Dodge - Dakota Quad Cab 4wd - Workshop Manual - 2002 - 2002

Factory Workshop Manual Make Dodge Model Dakota Quad Cab 4wd Engine and year V8-4.7L VIN N (2002) 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located in the steering column, near the ignition lock cylinder housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7 Sentry Key Immobilizer Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located in the steering column, near the ignition lock cylinder housing. The SKIM has an integral molded plastic halo- like antenna ring that extends from one side. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Central Timer Module (CTM), and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKIM also sends security indicator status messages to the CTM over the PCI data bus to tell the CTM how to operate the security indicator. The CTM then controls the security indicator in the ElectroMechanical Instrument Cluster (EMIC) through a hard wired security indicator driver circuit. The security indicator status message from the SKIM tells the CTM to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends security indicator status messages to the CTM 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9 test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKIM 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 SKIM will also send messages to the CTM to flash the security indicator whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector from the SKIM. 10. Remove the screw that secures the SKIM to the steering column. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper and lower shroud, and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Install the tilt lever knob. 10. Reinstall the steering column opening cover. 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations Door Module: Locations A Driver Door Module (DDM) located on the drivers door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 15 Door Module: Diagrams Driver Door Module C1 (EXcept Base) Driver Door Module C2 (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 16 Door Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) located on the drivers door trim panel, is used on all models equipped with power locks, power windows, and power mirrors. The DDM can be serviced without removing the front door trim panel. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light- Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module (CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 17 Door Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Fig.2 Driver Door Module Connector C1 Receptacle Fig.3 Driver Door Module Connector C2 Receptacle Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 18 Driver Door Module Switch Test (Part 1 Of 2) Driver Door Module Switch Test (Part 2 Of 2) 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 19 Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Antilock Brake Mounting Screws ............................................................................................................................................ 6 Nm (53 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 EBC 125 (RWAL) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 > Page 26 EBC 325 (ABS) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions Controller Antilock Brake: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 29 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 30 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 31 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 32 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 33 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 34 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 36 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 38 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 41 Controller Antilock Brake: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 42 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 43 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 44 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 45 Controller Antilock Brake: Connector Views Controller Antilock Brake C2 Controller Antilock Brake C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 46 Controller Antilock Brake: Electrical Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 48 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKE Fig.3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig.4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.To program the CAB refer to the Chassis Diagnostic. System self-test When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 49 The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the vehicle by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System REMOVAL NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Disconnect battery negative cable. (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB. (4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle. INSTALLATION NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs.). (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.) (4) Connect battery. (5) Bleed brake system Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 52 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Disconnect battery negative cable. Fig.5 Harness Connector Locks 2. Release the CAB harness connector locks, and remove the harness connectors from the CAB. Fig.6 Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 53 Fig.7 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 in. lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 58 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 59 Radiator Cooling Fan Motor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 60 Radiator Fan Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 61 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 66 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 67 Compressor Clutch Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 68 A/C Compressor Clutch Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 69 Compressor Clutch Relay: Description and Operation A/C COMPRESSOR CLUTCH RELAY The a/c compressor clutch relay is a International Standards Organization (ISO) micro relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the a/c heater control, the a/c loss of charge switch, the a/c pressure transducer and the evaporator fin probe. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 70 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3.If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2.If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4.If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5.If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 71 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.13 Power Distribution Center Location 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover 3. Connect the battery negative cable 4. Test the relay operation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 78 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 79 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 81 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 82 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 83 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 85 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 87 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Central Timer Module ( CTM ) Low Option: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 92 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 94 Central Timer Module ( CTM ) Low Option: Connector Views Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 95 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Central Timer Module ( CTM ) Low Option: Electrical Diagrams System Schematic Wiring Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 98 8w-45-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 99 8w-45-3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 100 8w-45-4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 101 8w-45-5 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 102 8w-45-6 (Base/Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 103 8w-45-7 (Midline/Highline) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 104 8w-45-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 105 8w-45-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 106 8w-45-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 107 8w-45-11 (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 108 8w-45-12 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 109 8w-45-13 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 110 8w-45-14 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 111 8w-45-15 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 112 8w-45-16 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 113 8w-45-17 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 114 8w-45-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 115 8w-45-19 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 116 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 117 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. Fig.1 Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel (Fig. 1). The base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM are used on vehicles that are equipped with one or more of those options. The CTM utilizes circuitry, and information carried on the Programmable Communications Interface (PCI) data bus network, along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Base and Highline CTM supports or controls the following features: Automatic Door Lock - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Low and High Beam Head Lamps - Optical Horn - Park Lamps - Speed Sensitive Intermittent Wiper Controls Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Horn Chirp - Optical Chirp - Panic Mode Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 118 - Power Door Locks - Programmable Features - Remote Keyless Entry - Remote Radio Switch Interface - Vehicle Theft Security System (VTSS) The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Programmable Communications Interface (PCI) data bus to control the volume, seek, and pre-set station advance functions of the optional radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. (Refer to BODY CONTROL/CENTRAL TIMER MODULE - DESCRIPTION) for more information on the high-line CTM. (Refer to REMOTE SWITCHES DESCRIPTION) for more information on this component. In addition, radio receivers connected to the PCI data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB III testing of the audio systems. Hard wired circuitry connects the CTM to the electrical system of the vehicle. Refer to the appropriate wiring information. All versions of the CTM for this model are serviced only as a complete unit. Many of the features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. If any of the CTM hardware components are damaged or faulty the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods. For diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. The Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The programming and all of the inputs allow the CTM to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM then performs those tasks and provides those features through both PCI data bus communication with other modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems. The CTM operates on battery voltage received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (RUN/START) circuit, and a fused ignition switch output (RUN/ACC) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position. The CTM is grounded to the chassis. Two of these ground circuits are on the left inner cowl panel near the CTM, while the third is near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store Diagnostic Trouble Codes (DTC) in memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Cargo lamp switch sense - Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch MUX - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (RUN/ACC) - Fused ignition switch output (RUN/START) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Low beam switch output - Park brake switch sense Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 119 - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch MUX - high line with power locks only - PCI bus circuit - Radio control MUX - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Cargo lamp driver - Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) - Ignition Staus - VTSS Status - Country Code Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 120 Central Timer Module ( CTM ) Low Option: Testing and Inspection The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the modules that provide inputs to, or receive outputs from, the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 121 Central Timer Module ( CTM ) Low Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 126 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 127 Fog/Driving Lamp Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 128 Fog Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 132 Horn Relay: Diagrams Horn Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 133 Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 134 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 135 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 136 Horn Relay: Testing and Inspection Fig. 2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 137 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the Junction Block (JB). 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated. 5. Install the fuse access panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 141 Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 142 Parking Lamp Relay: Diagrams Park Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 148 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 151 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 152 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 153 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 154 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 155 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 156 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 157 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 158 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 161 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 162 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 163 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 164 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 165 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 166 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 167 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations Central Timer Module ( CTM ) High Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 173 Central Timer Module ( CTM ) High Option: Diagrams Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 174 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 175 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information DANGER!!! ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection and remove any metal jewelry, such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 178 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "lock" position. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the Miller tool #8815 (not the wire end or terminal) in the connector. Do not probe a wire through the insulation; this will damage the wire and eventually cause the wire to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description Central Timer Module ( CTM ) High Option: Description and Operation System Description SYSTEM DESCRIPTION The body system on the Dakota (AN) and Dakota Quad Cab (AN84) consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 181 Central Timer Module ( CTM ) High Option: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/ Mechanical Instrument Cluster (EMIC and CTM) from the ACM via the PCI bus. The AIRBAG warning lamp and chime are the only point at which "symptoms" of a system malfunction can be observed by the customer. When- ever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF; there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Passenger Side Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. 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. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. SPECIAL TOOLS Some airbag diagnostic test use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver and Passenger Airbag, clockspring, or seat belt tensioner (use a jumper if needed). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 182 Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective components has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed squib wiring can be tested for open and shorted conditions. SEAT BELT TENSIONER Front seat belt systems incorporate Seat Belt Tensioner (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 183 remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Central Timer Module CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) - Horn Chirp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 184 - Optical Chirp The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. Chime System CHIME SYSTEM The chime system is built into the CTM. There are two chime rates - Low: 50 chimes per minute for reminders, and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left ON. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light ON the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Ignition OFF, cargo lights ON, drivers door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning (if vehicle speed>0) - Transmission temperature lamp - Turn signal ON reminder warning - Button pushed on compass mini-trip computer (reset) - ABS light ON - Over speed warning GULF COAST COUNTRY (GCC only) - Water in fuel (diesel) Compass/Mini-Trip Computer (CMTC) COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (Miles Per Gallon) or 1/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or 1/100 Km. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions and a chime will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 185 the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly OFF of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Head-lamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. Enhanced Accident Response ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Exterior Lighting EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition Off while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF, The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON, the delay will be canceled and the headlamps will turn OFF immediately. During the delay period, only the headlamps are turned ON and the park lamps/fog lamps are turned OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 186 The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned OFF and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. A 15 minute timeout is initiated if the ignition is OFF and the headlamp switch is cycled from OFF to ON (lamp mode). Heating & A/C System HEATING & A/C SYSTEM System Availability - A Single-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The A/C-Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - Provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The Single-Zone HVAC system uses: One, two-wire electronic blend door actuator. - One, two-wire electronic mode door actuator. - One, two-wire electronic recirculation door actuator. > A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. System Revisions The 2002 AN and AN84 HVAC system remains mostly carryover from 2001. Revisions to the 2002 HVAC system include: New Diagnostic Trouble Codes for a short high on the defog relay control circuit. - A new System Test called the Actuator Circuit Test. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRB III. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRB III. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator (if equipped) from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRB III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 187 - homes and repositions door actuators. - monitors for faults on the actuator circuits. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator (if equipped) to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator (if equipped) from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRB III. - monitors for faults on the actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test: CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause B fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: > indicates that a specific determination of which lines are shorted could not be made. > is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: > XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. > XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. > the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - After the Actuator Circuit Test is run on systems with less than six actuators: > the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). > If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed and the ignition is in the RUN or ACCY position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 188 sends voltage to the cargo lamps. When an unlock button of the RKE is pressed, the cargo lights will turn ON for 30 seconds, similar to the illuminated entry feature. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps and cargo lights due to the following. Leaving a door open, dome lamp switch ON, reading/ vanity lamp switch on or glove box door open for more than 15 minutes while the ignition is OFF. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the LOCK position, all the doors will lock. For unlocking, if the key is turned to the UNLOCK position once, only that door will unlock. If the key is then turned a second time to the UNLOCK position within 4 seconds, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The Highline CTM provides for Remote Keyless Entry (RKE). The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Vehicle Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 189 VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 190 - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Vehicle Theft Security/System VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. Windshield Wiper System WINDSHIELD WIPER SYSTEM The AN or AN84 truck utilize speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module ( CTM ) High Option: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - chime inoperative Chime Inoperative Exterior/Interior Lamps On & Driver Door Open Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Inoperative With Drivers Seat Belt Unfastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 193 Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire shorted to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 194 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central Timer Module Chime Sounds With Driver Seat Belt Fastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 195 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 196 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense shorted to ground - Central timer module - key-in ignition shorted Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in CTM - Central timer module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 197 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 198 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 199 Down or Page Up function to display the information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 200 Central Timer Module ( CTM ) High Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 201 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8443 Airbag Load Tool 8310 Airbag Load Tool Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Powertrain Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 206 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 207 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 208 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 209 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ............................................................................................................................. 3 - 5 Nm (30 - 40 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 210 Powertrain Control Module: Locations Powertrain Control Module Fig.8 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 213 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 214 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 218 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 220 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 221 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 222 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 223 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 227 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 228 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 230 Powertrain Control Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 231 Powertrain Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 232 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams 2002 Dodge 4.7L JTEC System Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 233 Powertrain Control Module: Description and Operation Fig.8 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/ crank/run position) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 234 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (2.5L engine only) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to- 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 235 - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal. auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 236 Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal.auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 237 PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Ignition Switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5 volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5 volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense circuit and is used to "wake up" the PCM. The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 238 SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 239 Powertrain Control Module: Service and Repair USE THE DRB III SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL Fig.9 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover over the electrical connectors. 3. Carefully unplug the 32-way connectors from PCM. 4. Remove the PCM mounting bolts and remove the PCM from vehicle. INSTALLATION 1. Install the PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the 32-way connectors for corrosion or damage. Repair as necessary 4. Install the 32-way connectors. 5. Install the cover over electrical connectors. 6. Reconnect the negative battery cable. 7. Use the DRB III scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 243 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 244 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 245 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 246 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 247 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 248 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 249 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Oxygen Sensor Downstream Heater Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 253 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 254 Oxygen Sensor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 255 Oxygen Sensor Downstream Heater Relay (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 256 Oxygen Sensor Relay: Description and Operation O2 HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 257 Oxygen Sensor Relay: Service and Repair Fig. 33 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 262 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 263 Fuel Pump Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 264 Fuel Pump Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 265 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 266 Fuel Pump Relay: 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, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 267 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 268 Fuel Pump Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 272 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 273 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 274 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 275 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 276 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 277 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 278 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 283 Airbag Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 284 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 285 Air Bag Control Module: Description and Operation AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. There are no external impact sensors. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) and Central Timer Module (CTM) from the ACM via the PCI bus. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn on the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For models equipped with the passenger airbag ON/OFF switch (all except Quad Cab), the ACM receives a resistor multiplexed input from this switch and provides a control output for the OFF indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag ON/OFF switch is set to the OFF position, the ACM turns on the passenger airbag ON/OFF switch OFF indicator and will internally disable the passenger airbag from being deployed if an impact is detected that is sufficient for an airbag deployment. The ACM also turns ON the ON/OFF switch OFF indicator for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. Following the bulb test, the ACM controls the status of the OFF indicator based upon the resistance of the input from the ON/OFF switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag ON/OFF switch circuits, and will turn ON the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits, on a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to 1 second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags and, on quad cab models, the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 286 test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 287 Air Bag Control Module: Service and Repair REMOVAL WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 288 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Motor Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 293 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 294 Starter Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 295 Engine Starter Motor Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 296 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 297 Starter Relay: Testing and Inspection Fig.14 Starter Relay The starter relay (Fig. 14) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear- shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 298 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig.15 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 15). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 306 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 307 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 309 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 310 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 311 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 313 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 315 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 319 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 320 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 324 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 325 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 326 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 327 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 328 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 332 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 333 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 334 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 335 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 340 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 341 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 342 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 343 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 344 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Rear Window Defogger Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 349 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 350 Heated Glass Element Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 351 Rear Window Defogger Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket- type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 356 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. (Refer to WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Remove/Install 4. Remove the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the wiper motor ground terminal. 8. Remove the wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the wiper arms onto the wiper pivots. (Refer to WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Front Wiper Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 360 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 361 Wiper Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 362 Front Wiper Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 363 Wiper Relay: Description and Operation The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. The wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the low speed brush of the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the wiper relay include: - The common feed terminal (30) is connected to the wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the wiper relay is de-energized, the common feed terminal is connected to the wiper park switch output through the CTM on the front wiper park switch sense circuit. The wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the wiper relay based upon its programming, inputs from the wiper and washer control circuitry of the multi-function switch, and inputs from the wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the ignition switch is in the On or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (RUN/ACC) current to the wiper motor low speed brush only when the wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the wiper motor low speed brush whenever the wiper relay control coil is de-energized and the Off position of the wiper control circuitry within the multi-function switch is selected. The wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 364 Wiper Relay: Testing and Inspection Fig.12 Wiper Relay The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. 1. Remove the wiper relay from the PDC. (Refer to WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (RUN/ACC) fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 87 of the wiper relay in the PDC whenever the ignition switch is in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (RUN/ACC) fuse in the JB through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 86 of the wiper relay in the PDC whenever the ignition switch is in the ON or ACCESSORY positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 365 Wiper Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.13 Power Distribution Centre - Typical 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for wiper relay identification and location. 4. Remove the wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper wiper relay location. 2. Position the wiper relay in the proper receptacle in the PDC. 3. Align the wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 371 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch (Premium) Passenger Cylinder Lock Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 372 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside the driver front door. The door cylinder lock switch is a resistor multiplexed switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the driver front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 373 Lock Cylinder Switch: Testing and Inspection 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 374 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 378 Remote Switch: Service Precautions 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 379 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULDESCRIPTION) for more information on this component. Fig.14 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION) for more information on this component. The remote radio switches are resistor multiplexed units that are hard wired to the high-line Central Timer Module (CTM) through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 380 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. 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. Fig.15 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control MUX circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 381 5. Check for continuity between the radio control MUX circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CTM and the Programmable Communications Interface (PCI) data bus. If not OK, repair the open radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 382 Remote Switch: Service and Repair 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 side airbag module from the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL) for the procedures. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Refer to ELECTRICAL/SPEED CONTROL for the procedures. Fig.16 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 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. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 383 4. Install the speed control switch onto the steering wheel. Refer to ELECTRICAL/SPEED CONTROL for the procedures. 5. Install the driver side airbag module onto the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - INSTALLATION) for the procedures. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 388 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the ON position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 389 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 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. 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. Fig.5 Power Lock 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 390 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 394 Power Mirror Switch: Service and Repair The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the outboard side of the seat cushion side shield. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 398 Power Seat Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 399 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch The switch is located on the outboard side of the seat cushion side shield. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 400 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Refer to the procedure. Fig.1 Power Seat Switch Continuity Test 3. With assistance from another person, use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch schematic and Continuity chart . If OK, see the Power Seat Track Diagnosis and Testing procedure. If not OK, replace the faulty power seat switch unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 401 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the two screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. INSTALLATION 1. Install the two screws that secure the power seat switch to the inside of the seat cushion side shield. 2. Install the wire harness connector on the power seat switch module. 3. Install the seat cushion side shield and power seat switch module on the seat as a unit. Refer to Body for the procedure. 4. Install the recliner lever on the recliner mechanism release shaft. 5. Install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 6. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Left Rear Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 409 Brake Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 inch lbs. Wheel Speed Sensors Rear Sensor Bolt 200 inch lbs. Rear Wheel Speed Sensor Mounting Bolt 200 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 418 Wheel Speed Sensor: Connector Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 419 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 422 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or signwave) is interpreted by the CAB. It then compares the frequency of the signwave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be ^ Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 423 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring Wheel Speed Sensor: Service and Repair Exciter Ring REMOVAL - EXCITER RING The exciter ring is mounted on the differential case. If the ring is damaged Refer to TONE RING REMOVAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 426 Wheel Speed Sensor: Service and Repair Front REMOVAL CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 427 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 428 Wheel Speed Sensor: Service and Repair Tone Wheel REMOVAL - TONE WHEEL The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 434 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 435 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 436 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 437 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 442 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 443 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 444 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 445 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 446 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 451 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 452 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 453 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 458 Ambient Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 459 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR Fig. 10 Ambient Temperature Sensor The ambient air temperature sensor is hardwired to the HVAC control and the HVAC control sends out a J1850 message to the overhead console. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the HVAC control head unit. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the HVAC control head unit. Based upon the resistance in the sensor, the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 460 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the HVAC control. If any portion of the ambient temperature sensor circuit fails or if PCI Bus information is missing, a (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 55 °C (140 °F), or if the sensor circuit is shorted. A (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40 °C (- 40 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing the Compass Mini-Trip Computer. SENSOR TEST 1. Turn the ignition OFF. Disconnect and isolate the battery negative cable. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE - 40 °C (- 40 °F) ................................................................................................................................... .................................................. 336 Kilohms 0 °C (32 °F) .................................................................. ........................................................................................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) ................................................................................................................................................. .......................... 17.99 - 21.81 Kilohms 20 °C (68 °F) ........................................................................ ................................................................................................... 11.37 - 13.61 Kilohms 25 °C (77 °F) .............................................................................................................................................................. ............... 9.12 - 10.86 Kilohms 30 °C (86 °F) ..................................................................................... .......................................................................................... 7.37 - 8.75 Kilohms 40 °C (104 °F) .......... .............................................................................................................................................................. ..... 4.90 - 5.75 Kilohms 55 °C (140 °F) ............................................................................................... ...................................................................................... 2.488 Kilohms The sensor resistance should read between these min/max values. If the resistance values are OK, refer to Sensor Circuit Test. If the resistance values are not OK, replace the sensor. SENSOR CIRCUIT TEST 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the HVAC control harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the HVAC control harness connector. There should be continuity If OK, go to Step 4.If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the HVAC control harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing of the Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 461 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.16 Ambient Temparature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 465 Blower Motor Switch: Description and Operation The heater-A/C blower motor is controlled by a five position (OFF plus 4 speeds) rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the blower control switch to the blower motor resistor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 466 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the a/c heater control from the instrument panel. Check for continuity between the ground circuit cavity of the a/c heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3.If not OK, repair the open circuit to ground as required. 3. With the a/c heater control wire harness connector unplugged, place the a/c heater blower control switch knob in any position except the OFF position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the a/c heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the a/c heater control connector and the blower motor resistor as required. If not OK, replace the faulty a/c heater control unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 467 Blower Motor Switch: Service and Repair REMOVAL The blower motor switch is integrated into the HVAC control assembly. 1. If the blower motor switch cannot be repaired or replaced and if damaged the entire HVAC control unit will require replacement. INSTALLATION The rear blower motor switch is not serviceable and is damaged or faulty replacement of the entire HVAC control assembly is required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 471 Evaporator Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 472 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the HVAC Control Module. The evaporator temperature sensor is used to switch the A/C compressor clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the HVAC control module. The A/C compressor clutch is switched OFF/ON when the probe temperatures are near 0 °C (32 °F). NOTE: Hysteresis and OFF/ON temperatures vary depending on the blower speed and software algorithm. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor is non-repairable, and must be replaced if found faulty Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 473 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove and isolate the battery negative cable. 2. Remove the access panel from the passenger side of the HVAC housing below the glove box housing to gain access to the evaporator temperature sensor. Fig.17 Evaporator Sensing Probe (typical) 3. Remove the evaporator temperature sensor from the evaporator. 4. Disconnect the evaporator temperature sensor lead wire from the wiring harness. 5. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor to the evaporator. 2. Connect the evaporator temperature sensor lead to the wiring harness. 3. Install the evaporator temperature sensor panel to the HVAC housing. Be sure to install the panel seal if seal is damaged replace as required. 4. Reinstall the battery negative cable to the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 478 Low Pressure Sensor / Switch: Locations The a/c loss of charge switch is located on the top of the accumulator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 479 Low Pressure Sensor / Switch: Description and Operation A/C LOSS OF CHARGE SWITCH The a/c loss of charge switch is located on the top of the accumulator. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the a/c compressor clutch. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 480 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the loss of charge switch wire harness connector from the switch on the accumulator fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cycling clutch switch. There should be continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or above, and no continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 481 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the loss of charge switch on the top of the accumulator. 3. Unscrew the loss of charge switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 487 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 488 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 490 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 491 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 492 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 496 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 501 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 503 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 506 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 507 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 508 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 512 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 % of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 % of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 513 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges under Electrical for Fuel Gauge testing. To test the gauge sending unit only it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 514 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector (Fig. 3). b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 515 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch (Fig. 5). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab (Fig. 6) to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 516 module is located inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 524 Brake Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 525 Brake Light Switch: Description and Operation The plunger type stop lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is used for the brake lamp, speed control and brake sensor circuits. The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits is closed until the plunger is depressed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 526 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 527 Brake Light Switch: Service and Repair REMOVAL Fig.2 Brake Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 ° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the mounting housing on the steering column. (Refer to ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ MULTI-FUNCTION SWITCH - REMOVAL). Fig.15 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 531 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER REMOVAL). 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure the upper shroud to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector. Fig.16 Multi-Function Switch 10. Remove the screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Remove the multi-function switch. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 N-m (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N-m (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper shroud and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N-m (20 in. lbs.). 9. Install tilt steering column knob. 10. Install the steering column opening cover onto the instrument panel. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 536 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 537 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 538 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 539 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 540 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 541 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 542 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 543 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 545 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 546 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 547 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 549 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 550 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 555 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 556 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 557 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 561 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 562 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement to access and depress the retaining latches on the glove box lamp and switch housing. Fig.3 Glove Box Lamp And Switch 4. Push the glove box lamp and switch out through the mounting hole in the instrument panel and disconnect the wire harness connector. 5. Remove the glove box lamp and switch from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector. 2. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 3. Push the glove box lamp and switch into the mounting hole until the retaining latches are fully seated 4. Close the glove box 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 566 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 567 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 568 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 572 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 573 Headlamp Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Headlamp Switch ................................................................................................................................. ................................................................... 158 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 574 Headlamp Switch: Description and Operation The headlamp switch controls the parking lamps, the headlamps, fog lamps,the interior lamps and the instrument cluster illumination. The headlamp switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are on and the driver door ajar switch is closed.The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. (Refer to HEADLAMP SWITCH - REMOVAL) for the service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 575 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Head Lamp Switch Continuity Table Fig.9 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 576 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 580 Horn Switch: Description and Operation Fig.3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane- type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly The horn switch is only serviced as a part of the driver side airbag trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag trim cover and horn switch must be replaced as a unit (Refer to /RESTRAINTS/DRIVER AIRBAG -REMOVAL) When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 581 Horn Switch: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 585 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 586 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 587 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 593 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 594 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 595 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 596 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 600 Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 604 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 605 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 606 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 607 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 608 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 612 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 613 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 614 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 615 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 619 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 620 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 621 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 622 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 623 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 627 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 631 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 632 Fuel Level Sensor: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector. b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 633 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 634 inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Torque Torque Intake Manifold Air Temp. Sensor 28 Nm 20 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 638 Intake Air Temperature (IAT) Sensor: Locations 4.7L The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 639 Intake Air Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 640 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 641 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Threaded Type Sensor 1. Disconnect electrical connector from sensor. Fig. 37 IAT - 4.7L (Threaded Type) 2. Remove sensor from intake manifold. Snap-In Type Sensor 1. Disconnect electrical connector from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 642 Fig. 39 IAT Sensor Tab/O-Ring - 4.7L (Snap-In Type) Fig. 38 IAT Sensor - 4.7L (Snap-In Type) 3. Gently lift on small plastic release tab and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION Threaded Type Sensor 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Snap-In Type Sensor 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 643 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Torque Torque MAP Sensor Mounting Screws 3 Nm 25 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 647 Manifold Absolute Pressure (MAP) Sensor: Locations 4.7L The MAP sensor is located on the front of the intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 648 Manifold Absolute Pressure Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 649 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When Manifold Absolute Pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops .10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 650 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 43 MAP And ECT Sensor Locations - 4.7L V-8 Engine REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 5. Connect electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 654 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 655 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 656 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque Torque Oxygen Sensor 30 Nm 22 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System 4.7L The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 662 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 663 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 664 Oxygen Sensor 2/2 Downstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 665 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 668 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 669 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. Refer to Wiring Diagrams to determine which relay is used. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on 2.5/3.9/5.2 and 5.9L engines. It is approximately 13.5 ohms on the 4.7L engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 670 package. Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 671 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. Fig. 46 Upstream Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 47 Downstream Oxygen Sensor Location - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 672 Fig. 48 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 49 Left/Right Oxygen Sensor Locations - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 673 Fig. 50 Oxygen Sensor Locations - 4.7L V-8 Engine WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 677 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 678 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 682 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 683 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 684 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 685 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 686 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 687 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 691 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 692 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 697 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 698 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 699 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 700 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 701 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 702 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 703 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 704 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 705 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 706 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 707 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 708 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 709 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 710 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 711 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 712 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 717 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 718 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 719 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 720 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 721 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 722 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 727 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 728 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 729 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 730 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 731 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 735 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 736 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 737 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 738 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 739 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 744 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 749 Passenger Airbag ON/OFF Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information Air Bag Deactivation Switch: Customer Safety Information WARNING - ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. - IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information > Page 752 Air Bag Deactivation Switch: Technician Safety Information WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 753 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG ON/OFF SWITCH The passenger airbag ON/OFF switch is standard equipment on all versions of this model except quad cab. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate and nomenclature, the key cylinder actuator, and a small round lens with the text "OFF" imprinted on it. The "ON" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel cluster 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 face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel cluster 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 of the instrument panel wire harness. The harness take out is equipped with a molded plastic connector insulator that 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 faulty or damaged, the switch must be replaced. 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. The ignition key is the only key or object that should ever be inserted into 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 side airbag ON/OFF switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, and 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 indicator), 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. NOTE: Do not turn the ON/OFF switch with the ignition on. 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 Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected and provide circuit diagnostics. The ON/OFF switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the ON/OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code, the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. When the passenger airbag ON/OFF switch is in the OFF position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the OFF indicator of the switch. The ACM will also illuminate the OFF indicator of the switch for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. The ACM will also store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag ON/OFF switch or indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag ON/OFF switch or the ACM, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 754 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the cluster bezel from the instrument panel. Fig.23 Passenger Airbag On/Off Switch 3. Remove the three screws that secure the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 4. Remove the passenger airbag ON/OFF switch and face plate from the cluster bezel as a unit. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 2. Install and tighten the three screws that secure the passenger airbag ON/OFF switch face plate to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the cluster bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS STANDARD PROCEDURE VERIFICATION TEST) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 758 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 759 Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole single throw, plunger actuated, momentary switch Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 760 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 765 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 766 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 767 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 768 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Clutch Switch: Diagrams Clutch Interlock Switch Jumper (A/T) Clutch Interlock Switch (M/T) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 772 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position switch is in the starter circuit. The switch is located on the clutch master cylinder push rod. OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 773 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION SWITCH REMOVAL AND INSTALLATION Switch is not serviced separately. If switch replacement is necessary, replace clutch master cylinder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 778 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 787 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 788 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 794 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 795 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 796 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 797 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 801 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 802 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 803 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 804 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 813 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 814 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 815 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 816 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 819 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 820 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 821 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 824 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 825 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 826 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 827 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 828 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 832 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 833 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 838 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 839 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 840 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 843 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 846 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 854 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 857 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 858 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 859 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 863 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 866 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 867 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 868 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly The rear window switch also contains the rear window defogger logic and timer circuitry, an LED defogger indicator lamp, the rear window defogger relay If faulty or damaged the entire controller assembly must be replaced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Passenger Door Power Window Switch (Except Base) Right Rear Power Window Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 876 Power Window Switch: Description and Operation On conventional cab and club cab models, the power windows are controlled by two-way switches integral to the power window and lock switch bezel on the passenger side and the Driver Door Module on the driver side of the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger side window. On quad cab models, the power windows are controlled by four two-way switches and a power window lockout switch that are integral to the Driver Door Module on the driver side front door trim panel. Additionally each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. On all models, the power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. On quad cab models, when the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, on quad cab models the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 877 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED (s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors only). For diagnosis of the driver side power window switch (Refer to DOOR MODULE - DIAGNOSIS AND TESTING). Unplug the wire harness connector from the switch unit. Passenger Door Switch 4. Test the power window switch continuity See the Power Window Switch Continuity chart to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 878 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel. 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 883 Washer Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 884 Washer Fluid Level Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Washer Fluid ................................................................................................................................ ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 885 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 886 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig.2 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 887 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications ALIGNMENT Alignment Specifications Dakota NOTE: All alignment specifications are in degrees. Alignment Specifications Dakota R/T Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 892 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. OPERATION CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 893 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 896 Alignment: Service and Repair Wheel Alignment Camber STANDARD PROCEDURE-CAMBER NOTE: 4x4 suspension height measurement must be performed before alignment. Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. Camber and Caster Adjustment STANDARD PROCEDURE-CAMBER AND CASTER ADJUSTMENT NOTE: 4x4 suspension height measurement must be performed before alignment. Camber and caster angle adjustments involve changing the position of the upper suspension arm Divot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. Caster STANDARD PROCEDURE-CASTER NOTE: 4x4 suspension height measurement must be performed before alignment. Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. Toe Adjustment STANDARD PROCEDURE-TOE ADJUSTMENT NOTE: 4x4 suspension height measurement must be performed before alignment. 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. Leave the engine running. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 897 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications. 6. Turn off engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 915 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 916 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 921 right front side of the engine block (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 922 Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service Precautions Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Torque ................................................................................................................................................. ....................................................... 27 Nm (20 ft. lbs) Plug Type ............................................................................................................................................ .............................................................. RC12MCC4 Electrode Gap ...................................................................................................................................... ................................................... 1.01 mm (0.040 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 933 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 934 Spark Plug: Description and Operation All engines use resistor type spark plugs. This engine is equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 935 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig.28 Normal Operation And Cold (Carbon) Fouling Normal Operating The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. On all engines except the 4.7L V-8, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. On the 4.7L V-8, gap growth will not average more than approximately 0.0015 in per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 936 Fig.29 Oil Or Ash Encrusted Oil or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.30 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 937 Fig.31 Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig.32 Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 938 Fig.33 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig.34 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 939 Spark Plug: Service and Repair REMOVAL Fig.35 Heat Shields - 3.9/5.2/5.9L Engines On 3.9L V-6 and 5.2/5.9L V-8 engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 4.7L V-8 Engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. Except 4.7L Engine: Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. 4.7L V-8 Engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 3. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition of coil O-ring and replace as necessary. Fig.37 Cable Removal 4. Except 4.7L: Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 5. Inspect spark plug condition. Refer to Spark Plug Conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 940 CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: The 4.7L V-8 engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. Except 4.7L Engine: When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Except 4.7L Engine: Tighten spark plugs to 35 - 41 Nm (26-30 ft. lbs.) torque. 3. Except 4.7L Engine: Install spark plug cables over spark plugs. 4. 4.7L V-8 Engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 5. 4.7L V-8 Engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 6. 4.7L V-8 Engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 944 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations > Page 951 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension on the 4.7L engine. These engines are equipped with an automatic belt tensioner (Fig. 4). The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 4.71, engines. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 955 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 17), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 17). 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. ACCESSORY DRIVE BELT DIAGNOSIS CHART PART 1 OF 2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 956 ACCESSORY DRIVE BELT DIAGNOSIS CHART PART 2 OF 2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 957 Drive Belt: Service and Repair REMOVAL CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREE ARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER. Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt tensioner. 1. Disconnect negative battery cable from battery. 2. Rotate belt tensioner until it contacts it's stop. Remove belt, then slowly rotate the tensioner into the free arm position. (Fig. 18). INSTALLATION Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt tensioner. 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 18). 2. Install new belt (Fig. 18). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 958 3. With the drive belt installed, inspect the belt wear indicator (Fig. 19). On 4.7L Engines only, the gap between the tang and the housing stop ( measurement A ) must not exceed 24 mm (0.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 975 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 981 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 982 Fluid Filter - A/T: Specifications Screws, Fluid Filter 35 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Removal Fluid Filter - A/T: Service and Repair Removal 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 57). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 985 Fluid Filter - A/T: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 986 Fluid Filter - A/T: Service and Repair Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 57). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4, type 9602 fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 987 Fluid Filter - A/T: Service and Repair Transmission Fill 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - 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 ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 993 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 994 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 998 Fuel Pump Pickup Filter: Service and Repair Fig. 33 Fuel Pump Inlet Filter - 2 Door Models Fig. 34 Fuel Pump Inlet Filter - 4 Door Models REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 33) or (Fig. 34). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. 4 Door Models: Remove filter by carefully prying it from bottom of pump module with 2 screwdrivers. Filter is snapped to module. 5. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 33) or (Fig. 34). The fuel pump module is located inside of Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 999 fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Daimler Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise (Fig. 100) to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 101) hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL WITHOUT AIR CONDITIONING 1. Partially drain cooling system.Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. WITH AIR CONDITIONING Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1007 If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. 1. Disconnect battery negative cable. 2. Partially drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body cables. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1008 13. Remove six bracket bolts. 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION WITHOUT AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. WITH AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2- to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Install drive belt. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. 16. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Lines At Compressor ............................................................................................................................. 23 Nm (17 Ft. Lbs) (200 ± 30 In .Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1012 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1013 Hose/Line HVAC: Description and Operation REFRIGERANT LINES The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut-block style fittings. A stat-O-seal type flat steel gasket with a captured compressible O-ring, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c pressure transducer switch. 4. Remove the fasteners and disconnect the refrigerant line couplers at the condenser and the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the accumulator. Tighten the fasteners to 22 ± 3.38 Nm (200 ± 30 in. lbs.). 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the fastener that secures the refrigerant line support bracket near the compressor. Tighten the mounting screw to 6.77 ± 1.7 Nm (60 ± 15 in. lbs.). 4. Plug in the wire harness connector to the pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1016 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the engine air filter housing. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the liquid line to evaporator coupler. 5. Disconnect the liquid line fastener at the condenser, and refrigerant line coupler at the evaporator. 6. Disengage the two clips that secure the liquid line to the inner fender shield. 7. Remove the liquid line from the vehicle. INSTALLATION High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Install the liquid line in the two clips on the inner fender shield. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator and install the secondary clip. Tighten the fastener at the condenser to 22.6 ± 3.38 Nm (200 ± 30 in. lbs.). 3. If the vehicle is so equipped, reinstall the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel. 4. Reinstall the engine air filter housing. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1017 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c pressure transducer switch. 4. Remove the fasteners and disconnect the refrigerant line couplers at the condenser and the accumulaton. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the accumulator. Tighten the fasteners to 22 ± 3.38 Nm (200 ± 30 in. lbs.). 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the fastener that secures the refrigerant line support bracket near the compressor. Tighten the mounting screw to 6.77 ± 1.7 Nm (60 ± 15 in. lbs.). 4. Plug in the wire harness connector to the pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Line Pressure Line 23 ft. lbs. Power Steering Line Return Line 23 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1021 Power Steering Line/Hose: Service and Repair HOSES REMOVAL- RETURN HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose at the gear. 5. Remove the pressure hose from the vehicle. REMOVAL- PRESSURE HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION - RETURN HOSE 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. Tighten the hose to 31 Nm (23 ft. lbs.). 3. Reconnect the return hose at the gear. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. INSTALLATION - PRESSURE HOSE 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 31 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the Full mark on the brake fluid reservoir. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1027 Brake Fluid: Fluid Type Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1028 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1029 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 an 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1030 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Clutch Fluid Reservoir Clutch fluid level is checked at the master cylinder reservoir. An indicator ring is provided on the outside of the reservoir. With the cap and diaphragm removed, fluid level should not be above indicator ring. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 1035 Clutch Fluid: Fluid Type Specifications Information not supplied by the manufacturer. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Page 1036 Clutch Fluid: Testing and Inspection MASTER CYLINDER - INSPECTION The clutch fluid reservoir, master cylinder, slave cylinder and fluid lines are pre-filled with fluid at the factory during assembly operations. The hydraulic system should not require additional fluid under normal circumstances. The reservoir fluid level will actually increase as normal clutch wear occurs. Avoid overfilling or removing fluid from the reservoir. Clutch fluid level is checked at the master cylinder reservoir. An indicator ring is provided on the outside of the reservoir. With the cap and diaphragm removed, fluid level should not be above indicator ring. To avoid contaminating the hydraulic fluid during inspection, wipe reservoir and cover clean before removing the cap. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .......................................... 12.3 Liters ( 13.0 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1041 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1042 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Specifications Differential Fluid - M/T: Specifications Differential Assembly Fluid Front Axle - C205F .............................................................................................................................................................. ................................................ 1.66 Liters (3.5 pts.) Rear Axle - 9 1/4 Inch .............................................................................................................................................................. ............................................ 2.32 Liters (4.9 pts.) ** Rear Axle - 8 1/4 Inch .............................................................................................................................................................. ........................................... 2.22 Liters (4.7 pts.) ** ** With Trac-Lok add 148 ml (5 oz) of friction modifier. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1050 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1051 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 42RE (A-500) 4 Speed 42RE - Automatic Transmission Service Fill ....................................................................................... .......................................................................................................... 3.8Liters (4.0 Qt) O-haul Fill ..... .............................................................................................................................................................. ................. 9.1 - 9.5Liters (19 - 20 Pt) 45RFE 4 Speed 45RFE - Automatic Transmission Service Fill 2WD .................................................................................................................................. .................................................... 5.2Liters (11.0 Pt) Service Fill 4WD .................................................................................................................................. .................................................... 6.2Liters (13.0 Pt) O-haul Fill ............................................................................................................................................ ................................................. 13.33Liters (28.0 Pt) 46RE (A-518) 4 Speed 46RE - Automatic Transmission Service Fill ........................................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) O-Haul Fill ............................................................................................................................................ ....................................... 9.1 - 9.5Liters (19 - 20 Pt) NOTE: Dry fill capacity depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1054 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 NOTE:Dextron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1055 Fluid - A/T: Service Precautions CAUTION: Never overfill the automatic transmission. Foaming and loss of fluid through the vent or filler tube, and malfunction, may result. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1056 Fluid - A/T: Description and Operation The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - 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 build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1059 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1060 Fluid - A/T: Testing and Inspection Fluid Contamination 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1061 Fluid - A/T: Testing and Inspection Standard Procedures 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DABS scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. (Fig. 56) 9. Adjust transmission fluid level shown on the dipstick according to the chart. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1062 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fill Fluid - A/T: Service and Repair Transmission Fill 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - 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 ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 1065 Fluid - A/T: Service and Repair Removal 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 57). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 1066 Fluid - A/T: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 1067 Fluid - A/T: Service and Repair Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 57). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4, type 9602 fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications NV1500 - Manual Transmission NV1500 Manual Transmission ............................................................................................................ ................................................... 2.3Liters (4.86 pts) Approximate dry fill or fill to bottom edge of the fill plug hole NV3500 - Manual Transmission NV3500 Manual Transmission ............................................................................................................................................................. 1.98 Liters (4.18 pts) Approximate dry fill or fill to bottom edge of the fill plug hole. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1072 Fluid - M/T: Fluid Type Specifications Mopar Manual Transmission Lubricant is recommended or equivalent for use in the manual transmissions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1073 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Assembly Fluid Front Axle - C205F .............................................................................................................................. .................................................. 1.66 Liters (3.5 pts.) Rear Axle - 9 1/4 Inch .......................................................................................................................... ................................................. 2.32 Liters (4.9 pts.) With Trac-Lok add 148 ml (5 oz) of friction modifier. Rear Axle - 8 1/4 Inch .......................................................................................................................... ................................................. 2.22 Liters (4.7 pts.) With Trac-Lok add 148 ml (5 oz) of friction modifier. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1078 Fluid - Differential: Fluid Type Specifications Front Axle - C205F The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. Rear Axle - 9 1/4 Inch The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. Rear Axle - 8 1/4 Inch The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. NOTE:Trac-lok equipped axles require a friction modifier be added to the lubricant. CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1079 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications Fluid - Transfer Case: Mechanical Specifications NV233 - Transfer Case Plug, Drain/Fill ............................................................................................... ............................................................................ 41 - 54 Nm (30 - 40 ft. lbs.) NV244 - Transfer Case Plug, Drain/Fill ............................................................................................... ............................................................................ 41 - 54 Nm (30 - 40 ft. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 1084 Fluid - Transfer Case: Capacity Specifications NV233 - Transfer Case Transfer Case Fluid ....................................................................................... ....................................................................................... 1.18 Liters (2.5 pts.) NV244 - Transfer Case Transfer Case Fluid ....................................................................................... ..................................................................................... 1.35 Liters (2.85 pts.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 1085 Fluid - Transfer Case: Fluid Type Specifications NV233 ....................................................................................................................................... Mopar ATF +4, type 9602, Automatic Transmission Fluid NV244 ....................................................................................................................................... Mopar ATF +4, type 9602, Automatic Transmission Fluid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Standard Procedure - NV233 Transfer Case Fluid - Transfer Case: Service and Repair Standard Procedure - NV233 Transfer Case NV233 - Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case (Fig. 70). 1. Raise vehicle. 2. Position drain pan under transfer case. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 41 - 54 Nm (30 - 40 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar ATF +4, type 9602, Automatic Transmission fluid. 7. Install and tighten fill plug to 41 - 54 Nm (30 - 40 ft. lbs.). 8. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Standard Procedure - NV233 Transfer Case > Page 1088 Fluid - Transfer Case: Service and Repair Standard Procedure - NV244 Transfer Case NV244 - Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case (Fig. 77). 1. Raise vehicle. 2. Position drain pan under transfer case. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 41 - 54 Nm (30 - 40 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar ATF +4, type 9602, Automatic Transmission fluid. 7. Install and tighten fill plug to 41 - 54 Nm (30 - 40 ft. lbs.). 8. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity w/filter .................................................................................................................. ....................................................................... 6.0 Qt Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1093 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ................................... 5W-30 SAE or 10W-30 SAE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1094 Engine Oil: Service Precautions American Petroleum Institute (API) Engine Oil Identification Symbol For best performance and maximum protection for all engines under all types of operation, select only engine oils that meet American Petroleum Institute (API) certification and SAE viscosity standards. This symbol on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1095 Engine Oil: Service and Repair STANDARD PROCEDURE-ENGINE OIL SERVICE WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1100 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1101 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1102 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications The power steering fluid reservoir is equipped with a dipstick to indicate fluid level. Fluid level should be at the "HOT" mark if the vehicle has been operating; "FULL COLD" if not operated for at least 6 hrs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1105 Power Steering Fluid: Fluid Type Specifications Type Mopar ATF+4 Automatic Transmission Fluid Use only Mopar ATF+4 Automatic Transmission Fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1106 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1107 Power Steering Fluid: Description and Operation FLUID DESCRIPTION The recommended fluid for the power steering system is Mopar ATF+4, MS 9602. Mopar ATF+4, MS 9602, Automatic Transmission Fluid when new is red in color. The ATF 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 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1108 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR (MS-9602) 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. Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602). Do not overfill the power steering system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ....................................................... 32 oz. (0.907 kg) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1113 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 1116 http://www.macsw.org/ Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 1117 Refrigerant: Technician Safety Information WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING AN AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED, BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Page 1118 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Page 1119 Refrigerant: Testing and Inspection If the air conditioning system is not cooling properly, determine if the refrigerant system is fullycharged. If the refrigerant system is low or empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. An electronic leak detector designed for R-134a refrigerant, or a fluorescent R-134a leak detection dye and a black light are recommended for locating and confirming refrigerant system leaks. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. To detect a leak in the refrigerant system with an electronic leak detector, perform one of the following procedures: SYSTEM EMPTY 1. Evacuate the refrigerant system. 2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. With the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 5. To inspect the evaporator for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, and the mode control switch in the recirculation mode. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run with the air conditioning system turned ON for five minutes. 3. With the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, and the mode control switch in the recirculation mode. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery Refrigerant: Service and Repair Refrigerant - Recovery STANDARD PROCEDURE - REFRIGERANT RECOVERY A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 1122 Refrigerant: Service and Repair Refrigerant - Evacuate STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and could damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant system, use the following procedure: 1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold gauge set (if required) to the refrigerant system of the vehicle and recover refrigerant.. 2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn OFF the vacuum pump. a. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. See Refrigerant System Leaks in the Diagnosis and Testing for the procedures. b. If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. 3. Close all of the valves, and turn OFF the charging station vacuum pump. 4. The refrigerant system is now ready to be charged with R-134a refrigerant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 1123 Refrigerant: Service and Repair Refrigerant - Charge STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system. A 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Total System ........................................................................................................................................ ......................................................... 210 ml (7.1 oz.) Accumulator ......................................................................................................................................... ............................................................. 90 ml (3 oz.) Condenser ........................................................................................................................................... ............................................................... 30 ml (1 oz.) Evaporator ........................................................................................................................................... .............................................................. 60 ml (2 oz.) Compressor ......................................................................................................................................... ..................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1128 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... ............................................................. SP-15 PAG PAG - PolyAlkylene Glycol Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1129 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The SD7H15 compressor used in this vehicle is designed to use an SP-20 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1130 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities STANDARD PROCEDURE - REFRIGERANT OIL LEVEL When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The accumulator, evaporator, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a accumulator, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1134 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams Circuit Breaker: Diagrams Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Page 1139 Circuit Breaker Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Page 1140 Circuit Breaker: Description and Operation Automatic resetting circuit breakers in the junction block are used to protect the power seat and power window system circuits. These circuit breakers can protect the systems from a short circuit, or overload condition caused by an obstructed or stuck seat adjuster, window glass or regulator. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Page 1141 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block > Page 1146 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1149 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1150 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1151 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1152 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1153 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1154 Fuse: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1155 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1158 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1159 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1160 Fuse: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1161 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block > Page 1166 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Fuse Block: Connector Views Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Junction Block C11 Junction Block C12 Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 Fuse Block: Electrical Diagrams 8w-12-6 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 8w-12-7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 8w-12-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 8w-12-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 8w-12-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 8w-12-11 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 8w-12-12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 8w-12-13 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 8w-12-14 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 8w-12-15 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 8w-12-16 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 8w-12-17 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 8w-12-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 8w-12-19 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 8w-12-20 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 8w-12-21 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 8w-12-22 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1210 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1213 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1214 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1215 Fuse Block: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1216 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1217 Fuse Block: Description and Operation JUNCTION BLOCK Fig.6 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 6). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1218 Fuse Block: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 7). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig.8 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 8). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1219 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block > Page 1224 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1227 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1228 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1229 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1230 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1231 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1232 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1233 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Page 1234 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1237 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1238 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1239 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1240 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1241 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1242 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1243 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Locations Coolant Level Indicator Lamp: Locations The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Locations > Page 1248 Coolant Level Indicator Lamp: Description and Operation COOLANT LOW INDICATOR The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. The coolant low indicator consists of a stenciled cutout of the words "LOW COOLANT" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "LOW COOLANT" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The coolant low indicator is serviced as a unit with the instrument cluster. The coolant low indicator gives an indication to the vehicle operator when the engine coolant level is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface PCI data bus. The coolant low indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the coolant low indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the coolant low indicator is illuminated for about two seconds as a bulb test. - Coolant Low Lamp-ON Message - Each time the cluster receives a message from the PCM indicating the engine coolant level is low, the coolant low indicator will be illuminated, and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine coolant level is not low, 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 coolant low indicator is cycled OFF and then ON again by the appropriate lamp-OFF and lamp-ON messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant level through the low coolant level switch, then sends the proper messages to the instrument cluster. For further diagnosis of the coolant low indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the low coolant level switch, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the coolant low indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1252 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ................................................................... LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1253 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a 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 icon to appear in amber through the translucent outer layer of the overlay when the indicator 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. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) 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 seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-OFF message automatically Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters. - Communication Error - If the cluster receives no lamp-ON message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-on message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-OFF messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle did not have an Oil Change Reminder Light. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Application and ID > Page 1257 Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Application and ID > Page 1258 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Fig.6 Correct Vehicle Lifting Locations - Typical STANDARD PROCEDURE HOISTING RECOMMENDATIONS Floor Jack CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - Aluminum differential. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. When properly positioned, a floor jack can be used to lift a Dakota vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. Hoist WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVE TRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: DO NOT LET THE REAR WHEELS/AXLE HANG UNSUPPORTED WHEN THE VEHICLE IS LIFTED WITH THE PARKING BRAKE APPLIED. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 6). A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. A ramp-type, drive-on hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation SPARE TIRE DESCRIPTION The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation > Page 1267 Spare Tire: Service and Repair SPARE TIRE WINCH REMOVAL 1. Remove spare tire. 2. Remove bolts attaching spare tire winch to crossmember. 3. Disengage clip attaching extension tube to spare tire winch. 4. Separate spare tire winch from vehicle. INSTALLATION 1. Position extension tube on spare tire winch and engage clip. 2. Position spare tire winch on vehicle. 3. Install bolts attaching spare tire winch to spare tire bracket. 4. Install spare tire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 1272 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1273 Wheels: Specifications Wheel Lug Nut 85 to 115 ft. lbs. CAUTION: DO NOT USE CHROME PLATED LUG NUTS WITH CHROME PLATED WHEELS. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1274 Wheels: Description and Operation WHEELS DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1275 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Half Shaft Nut ...................................................................................................................................... .............................................. 244 Nm (180 Ft Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1287 Wheel Fastener: Specifications Caution: Do not use chrome plated lug nuts with chrome plated wheels. Wheel Lug Nut 1/2 x 20 with 60 degree Cone 85-115 ft.lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1291 Jump Starting: Service and Repair STANDARD PROCEDURE JUMP STARTING PROCEDURE WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary. - Frozen battery - Yellow or bright color test indicator, if equipped. - Low battery fluid level. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn OFF all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn OFF all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. Fig.7 Jumper Cable Clamp Connections 5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible. 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1292 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 mm.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: Disconnect BLACK cable clamp from engine ground on disabled vehicle. - When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. - Disconnect RED cable clamp from battery positive terminal on disabled vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair Towing Information: Service and Repair STANDARD PROCEDURE Fig.8 Tow Vehicles With Approved Equipment TOWING RECOMMENDATIONS A vehicle equipped with an SAE approved Wheel- lift towing device can be used to tow all Short Bed DAKOTA vehicles. Long Bed vehicles must be towed with a Flat-bed device (Fig. 8). When towing a 4WD vehicle, use tow dollies under the opposite end of the vehicle. SAFETY PRECAUTIONS NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flat bed device to transport a loaded vehicle. GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. RAMP ANGLE If a vehicle with flat bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. TOWING WHEN KEYS ARE NOT AVAILABLE When the vehicle is locked and keys are not available, use a flat bed hauler. A Sling-type device can be used on 4WD vehicles provided all the wheels are lifted OFF the ground using tow dollies. TWO WHEEL DRIVE VEHICLE TOWING TOWING-REAR END LIFTED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Page 1296 Fig.9 Short Bed Vehicle Towing-Typical Fig.10 Long Bed Vehicle Towing-Typical CAUTION: Short bed vehicle must be towed with a Wheel-lift device (Fig. 9) or transported on a flat bed (Fig. 10) Long bed vehicle must be transported on a flat bed 2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph). 1. Attach wheel lift device to rear wheels. 2. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 3. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 4. Secure steering wheel in straight ahead position with a clamp device designed for towing. 5. Verify that steering components are in good condition. 6. Shift the transmission to NEUTRAL. TOWING-FRONT END LIFTED When lifting from the front end, all vehicles must be towed with a Wheel-lift device or transported on a flat bed. 1. Attach Wheel-lift device to front wheels. 2. Attach the safety chains to the disabled vehicle at the frame rails. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 3. Turn the ignition switch to the OFF position to unlock the steering wheel. TWO WHEEL DRIVE-MANUAL AND AUTOMATIC TRANSMISSION Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. FOUR WHEEL DRIVE VEHICLE TOWING FOUR WHEEL DRIVE TOWING-REAR END LIFTED CAUTION: Short bed vehicles must be towed with a Wheel-lift device (Fig. 9) or transported on a flat bed. Long bed vehicles must be transported on a flat bed (Fig. 10). When using a Wheel-lift device, all wheels must be lifted off the ground using tow dollies. 1. Raise the front of the vehicle off the ground and install tow dollies under front wheels. 2. Attach wheel lift device to rear wheels. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Page 1297 3. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 5. Secure steering wheel in straight ahead position with a clamp device designed for towing. 6. Shift the transfer case to NEUTRAL. FOUR WHEEL DRIVE TOWING-FRONT END LIFTED When lifting from the front end, all vehicles must be towed with a wheel-lift device or transported on a flat bed. 1. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. 2. Attach wheel lift device to front wheels. 3. Attach the safety chains to the disabled vehicle at the frame rails. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Shift the transfer case to NEUTRAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Fig.6 Correct Vehicle Lifting Locations - Typical STANDARD PROCEDURE HOISTING RECOMMENDATIONS Floor Jack CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - Aluminum differential. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. When properly positioned, a floor jack can be used to lift a Dakota vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. Hoist WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVE TRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: DO NOT LET THE REAR WHEELS/AXLE HANG UNSUPPORTED WHEN THE VEHICLE IS LIFTED WITH THE PARKING BRAKE APPLIED. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 6). A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. A ramp-type, drive-on hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1306 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications Camshaft Bearing: Specifications Camshaft Bearing Bore Specifications Camshaft Bearing Journal Diameter .................................................................................................................................................... 1.0227 - 1.0235 inch Camshaft Bearing Clearance ............................................................................. ..................................................................................... 0.001 - 0.0026 inch Camshaft Bearing Clearance (Max.) ................................................................................................................................. ................................. 0.0026 inch Camshaft Bearing Cap Bolt ........................................................... ....................................................................................................................... 100 in. lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications > Page 1312 Camshaft Bearing: Specifications Camshaft Bearing Cap Torque & Sequence Camshaft Bearing Caps - Left Side Left Side Camshaft Camshaft Bearing Caps - Right Side Right Side Camshaft Tighten the bearing cap bolts in 1/2 turn increments following the sequence shown to 11 Nm (100 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications > Page 1313 Camshaft Bearing: Specifications Bearing Cap Bolts 100 inch lbs. working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward. Bore Diameter 1.0245- 1.0252 inch Bearing Journal Diameter 1.0227 - 1.0235 inch Bearing Clearance 0.001 - 0.0026 inch Bearing Clearance 0.0026 inch End Play 0.003 - 0.0079 inch End Play (MAX) 0.0079 inch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1314 Camshaft Bearing: Service and Repair Camshaft Bearing Caps - Left Side Left Side Camshaft Camshaft Bearing Caps - Right Side Right Side Camshaft Tighten the bearing cap bolts in 1/2 turn increments following the sequence shown to 11 Nm (100 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Left Camshaft Camshaft: Description and Operation Left Camshaft DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Left Camshaft > Page 1322 Camshaft: Description and Operation Right Camshaft DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft Camshaft: Service and Repair Left Camshaft REMOVAL CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT forcefully rotate the camshafts or crankshaft Independently of each other. Severe valve and/or piston damage can occur. CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet. 1. Remove cylinder head cover. 2. Set engine to TDC cylinder # 1, camshaft sprocket V8 marks at the 12 o'clock position. 3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition. 4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur. 5. Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide (Fig. 28). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1325 6. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 29). 7. Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neutral position (no valve load). 8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft. 9. Remove the camshaft bearing caps and the camshaft. INSTALLATION 1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps. 2. Position the camshaft into the cylinder head. 3. Install the camshaft bearing caps, hand tighten the retaining bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1326 Camshaft Bearing Caps - Left Side 4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward. 5. Torque the camshaft bearing cap retaining bolts to 11 Nm (100 in. lbs.). 6. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (Two links marked during removal). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1327 7. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over torque resulting in bolt failure. 8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten. 9. Remove Special Tool 8350 timing chain wedge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1328 10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 Nm (90 ft. lbs.). 11. Install the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1329 Camshaft: Service and Repair Right Camshaft REMOVAL 1. Remove the cylinder head covers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1330 CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT forcefully rotate the camshafts or crankshaft independently of each other. Severe valve and/or piston damage can occur. CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use special tool 8350 will result in hydraulic tensioner ratchet over extension, Requiring timing chain cover removal to re-set the tensioner ratchet. 2. Set engine to TDC cylinder # 1, camshaft sprocket V8 marks at the 12 o'clock position. 3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket (2) to aid in installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1331 CAUTION: Do not hold or pry on the camshaft target wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition. 4. Loosen but DO NOT remove the camshaft sprocket retaining bolt (2). Leave bolt snug against sprocket (3). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1332 NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur. 5. Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1333 6. Remove the camshaft position sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1334 NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. 7. Hold the camshaft with adjustable pliers (1) while removing the camshaft sprocket bolt (2) and sprocket (3). 8. Using the pliers (1), gently allow the camshaft to rotate 45° counter-clockwise until the camshaft is in the neutral position (no valve load). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1335 9. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft. 10. Remove the camshaft bearing caps and the camshaft. INSTALLATION 1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps. 2. Position the camshaft into the cylinder head. 3. Install the camshaft bearing caps, hand tighten the retaining bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1336 Camshaft Bearing Caps - Right Side 4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward. 5. Torque the camshaft bearing cap retaining bolts to 11 Nm (100 in. lbs.). 6. Position the camshaft drive gear into the timing chain aligning the V8 mark (2) between the two marked chain links (Two links marked during removal). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1337 7. Using the adjustable pliers(1), rotate the camshaft until the camshaft sprocket dowel (2) is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over torque resulting in bolt failure. 8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten. 9. Remove timing chain wedge special tool 8350 (3). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1338 10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (2), torque the camshaft sprocket retaining bolt (4) to 122 Nm (90 ft. lbs.). 11. Install the camshaft position sensor. 12. Install the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required. 3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Oil leak or excessive cam bore wear in cylinder head. 11. Faulty lash adjuster. - Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. - Remove suspected lash adjusters, and replace. - Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Page 1345 Rocker Arm Assembly: Service and Repair REMOVAL NOTE: Disconnect the battery negative cable to prevent accidental starter engagement. 1. Remove the cylinder head cover. 2. For rocker arm removal on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke. 3. For rocker arm removal on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke. 4. For rocker arm removal on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke. 5. For rocker arm removal on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke. 6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 45). INSTALLATION CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters. NOTE: Coat the rocker arms with clean engine oil prior to installation. 1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke. 2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke. 3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke. 4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke. 5. Using special tool 8516 press downward on the valve spring, install rocker arm (Fig. 45). 6. Install the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance 0.0004 - 0.0019 inch Piston Pin Bore Diameter (Interference Fit) 0.0009 - 0.0018 inch Bearing Bore Out of Round (MAX) 0.0002 inch Total Weight Bearing 19.5771 Ounces Connecting Rod Cap-Bolts 20 ft. lbs. PLUS 90°TURN Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1350 Connecting Rod Bearing: Service and Repair STANDARD PROCEDURE-CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 50) (Fig. 51). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 52). Replace any bearing that shows abnormal wear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1351 Inspect the connecting rod journals for signs of scoring, nicks and burrs. Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted connecting rods. 1. Wipe the oil from the connecting rod journal. 2. Lubricate the upper bearing insert and install in connecting rod. 3. Use piston ring compressor and Guide Pins Special Tool 8507 (Fig. 53) to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"s near the piston wrist pin bore should point to the front of the engine. 4. Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plastigage across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock. 5. Install bearing cap and connecting rod on the journal and tighten bolts to 27 Nm (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1352 6. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (Fig. 54). Refer to Engine Specifications for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod. 7. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation. 8. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: 9. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly. 10. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 Nm (20 ft. lbs.) plus a 90° turn. Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange (Fig. 55). Refer to Engine Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Bearing Clearance 0.0004 - 0.0019 in Side Clearance 0.004 - 0.0138 in Piston Pin Bore Diameter (Interference Fit) 0.0009 - 0.0018 inch Bearing Bore Out of Round (MAX) 0.0002 inch Total Weight (Less Bearing) 19.5771 oz (US) Connecting Rod Cap Bolts 1st step 20 ft.lb 2nd Step Plus 90 deg. Turn Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1357 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1358 Connecting Rod: Description and Operation "For information regarding this component please refer to Piston description and operation" Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Bolt 130 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Main Bearing Journal Diameter Minimum 2.4996 in Maximum 2.5005 in Bearing Clearance Minimum 0.0008 in Maximum 0.0021 in Out of Round Maximum 0.0002 in Taper Maximum 0.0004 in Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1366 Crankshaft Main Bearing: Specifications Torque Specifications Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location. Torque the bolts in the sequence shown. Tighten bolts A - L to 54 Nm (40 ft. lbs.). - Tighten bolts 1 - 10 to 2.8 Nm (25 in. lbs.). - Turn bolts 1 - 10 an additional 90 °. - Tighten bolts A1- A6 to 27 Nm (20 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Fitting Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Fitting STANDARD PROCEDURE-CRANKSHAFT MAIN BEARING - FITTING MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008 mm (0.0004 inch) and maximum out of round is 0.005 mm (0.002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Fitting > Page 1369 Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Inspection INSPECTION Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Fig. 64). NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced. Inspect the back of the inserts for fractures, scrapings or irregular wear patterns. Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Fitting > Page 1370 Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Selection CRANKSHAFT MAIN BEARING SELECTION The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft position sensor target wheel has grade identification marks stamped into it (Fig. 63). These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5. The crankshaft position sensor target wheel is mounted to the number 8 counter weight on the crankshaft. NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is. MAIN BEARING SELECTION CHART-4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Diameter 2.4996 - 2.5005 inch Bearing Clearance 0.0008 - 0.0021 inch Out of Round (MAX) 0.0002 inch Taper (Max) 0.0004 inch End Play 0.0021 - 0.0112 inch End Play (MAX) 0.0112 inch Connecting Rod Journal Diameter 2.0076 - 2.0082 inch Bearing Clearance 0.0006-0.0022 inch Out of Round (MAX) 0.0002 inch Taper (MAX) 0.0004 inch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1374 Crankshaft: Description and Operation DESCRIPTION The crankshaft is constructed of nodular cast iron. The crankshaft is a cross shaped four throw design with eight counterweights for balancing purposes. The crankshaft is supported by five select fit main bearings with the number three serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The number eight counterweight has provisions for crankshaft position sensor target wheel mounting. The select fit main bearing markings are located on the rear side of the target wheel. The crankshaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1375 Crankshaft: Service and Repair REMOVAL NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle. 1. Remove the engine. 2. Remove the engine oil pump. CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan. 3. Remove oil pan. 4. Remove the oil pump pickup tube and oil pan gasket /windage tray. 5. Remove the bedplate mounting bolts. Note the location of the three stud bolts for installation. 6. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway. NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause sever damage to the crankshaft. NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are on both the left and right sides, only the left side is shown. 7. Carefully pry on the pry points (Fig. 57) to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft. 8. Remove the crankshaft. 9. Remove the crankshaft target wheel. INSPECTION NOTE: Thoroughly inspect the connecting rod bearing bores and main bearing bores for scoring, bluing or severe scratches. Further disassembly may be required. If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1376 cylinder block main bearing bores show damage the engine must be replaced. 1. If required, remove the main bearing halves from the cylinder block and bedplate. 2. Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue. 3. Inspect the bedplate main bearing bores for cracks, scoring or severe bluing. If either condition exists the engine must be replaced. 4. Inspect the crankshaft thrust washer for scoring, scratches or bluing. If either condition exist replace the thrust washer. 5. Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary. INSTALLATION CAUTION: Main bearings are select fit. Refer to Crankshaft Main Bearings for proper bearing selections. 1. Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the target wheel retaining screws prior to installation. 2. Install the crankshaft target wheel. Torque the mounting screws to 22 Nm (21 ft. lbs.). 3. Position crankshaft in cylinder block. 4. Install the thrust washers (Fig. 58). CAUTION: The bedplate to cylinder block mating surface must be coated with sealant prior to installation. Failure to do so will cause severe oil leaks. NOTE: The installation time to install the bedplate after the sealant has been applied is critical. NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1377 5. Apply a 2.5 mm (0.100 inch) (Fig. 59) bead of Mopar Gen. II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown (Fig. 60). 6. Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block. NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1378 7. Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown (Fig. 61). - Tighten bolts A-L to 54 Nm (40 ft. lbs.) - Tighten bolts 1-10 to 2.8 Nm (25 in. lbs.) - Turn bolts 1-10 an additional 90°. - Tighten bolts Al- A6 to 27 Nm (20 ft. lbs.) 8. Measure crankshaft end play. 9. Install the connecting rods and measure side clearance. 10. Position the oil pan gasket/windage tray, using a new O-ring, install the oil pickup tube. Torque the bolt to 28 Nm (20 ft. lbs.) torque the nuts to 28 Nm (20 ft. lbs.). 11. Install the oil pan. Torque the retaining bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 62). 12. Install the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. An optional engine block heater (Fig. 4) is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. OPERATION Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded, three wire extension cord activates the heating element warming the engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1382 Engine Block Heater: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE BLOCK HEATER If the unit does not operate (Fig. 5), possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1383 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery 2. Drain coolant from radiator. 3. Raise vehicle. 4. Remove engine cylinder block drain plug(s) located on the sides of cylinder block above the oil pan rail (Fig. 6). 5. Remove power cord from block heater. 6. Loosen screw at center of block heater. Remove heater assembly (Fig. 7). INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly with element loop pointing at twelve o'clock (Fig. 7). 3. With block heater fully seated, tighten center screw to 2 Nm (17 in. lbs.) torque. 4. Refill cooling system. 5. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL 1. Drain the cooling system. 2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (Fig. 56) 3. Using a suitable pair of pliers, grasp the core plug and remove. INSTALLATION NOTE: Thoroughly clean core plug bore, remove all of the old sealer. 1. Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent. NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately. 2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 inch) inside the lead in chamfer. 3. Refill the cooling system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Damper Bolt 130 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1390 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative cable from battery 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove radiator upper hose. 5. Remove upper fan shroud. 6. Using Special Tools 6958 Spanner with Adapter Pins 8346, loosen fan and viscous assembly from water pump (Fig. 82), 7. Remove fan and viscous assembly. 8. Disconnect electrical connector for fan mounted inside radiator shroud. NOTE: Transmission cooler line snaps into shroud lower right hand corner. 9. Remove crankshaft damper bolt, Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1391 10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller (Fig. 83). INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512-A, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Align crankshaft damper slot with key in crankshaft. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft. 2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod (Fig. 84). Once assembled coat the threaded rod's threads with Mopar Nickel Anti Seize or (Loctite No. 771). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1392 3. Using Special Tool 8512-A, press damper onto crankshaft (Fig. 85). 4. Install then tighten crankshaft damper bolt to 175 Nm (130 ft. lbs.). 5. Install fan blade assembly. 6. Install radiator upper shroud and tighten fasteners to 11 Nm (95 in. lbs.). 7. Connect electrical connector for shroud fan. 8. Install radiator upper hose. 9. Install accessory drive belt. 10. Refill cooling system. 11. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Material Aluminum Alloy Diameter 3.6605 inch Weight 12.96 oz Ring Groove Diameter No. 1 3.296 - 3.269 inch No. 2 3.261 - 3.310 inch No. 3 3.302 - 3.310 inch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1396 Piston: Description and Operation DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. The anodized top ring groove and crown has been replaced with a coated top ring that is blue in color. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Cleaning and Inspection CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. Piston to Cylinder Bore Fitting STANDARD PROCEDURE-PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (0.0001 inch) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90°) to the axis of the crankshaft at point A and then take an additional bore reading 90° to that at point B (Fig. 73). 3. The coated pistons will be serviced with the piston pin and connecting rod preassembled. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1399 4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results (Fig. 72). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (0.0001 inch) increments is required. 5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1400 Piston: Removal and Replacement REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: - Oil pan and gasket/windage tray. - Cylinder head covers. - Timing chain cover. - Cylinder head(s). 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig. 74). CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1401 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads (Fig. 75). 5. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine (Fig. 76). 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1402 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 Nm (20 ft. lbs.) plus 90°. 10. Install the following components: - Cylinder head(s). - Timing chain and cover. - Cylinder head covers - Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Top Compression Ring 0.0146- 0.0249 inch Second Compression Ring 0.0146- 0.0249 inch Oil Control (Steel Rails) 0.0099- 0.30 inch Side Clearance Top Compression Ring 0.0020 - 0.0037 inch Second Compression Ring 0.0016 - 0.0031 inch Oil Ring (Steel Ring) 0.0007 - 0.0091 inch Ring Width Top Compression Ring 0.057 - 0.058 inch Second Compression Ring 0.057 - 0.058 inch Oil Ring (Steel Rails) 0.017 - 0.018 inch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1406 Piston Ring: Service and Repair STANDARD PROCEDURE - PISTON RING FITTING Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Wipe the cylinder bore clean. 2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch) from bottom of cylinder bore. 3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder. 4. Using a feeler gauge check the ring end gap (Fig. 77). Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 5. Measure the ring side clearance as shown (Fig. 78) make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification. 6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1407 PISTON RING SPECIFICATION CHART 7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: - Oil ring expander. - Upper oil ring side rail. - Lower oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 8. Install the oil ring expander. 9. Install upper side rail (Fig. 79) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1408 10. Install No. 2 intermediate piston ring using a piston ring installer (Fig. 80). 11. Install No. 1 upper piston ring using a piston ring installer (Fig. 80). 12. Position piston ring end gaps as shown in (Fig. 81). It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 1417 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1418 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Page 1422 Rocker Arm Assembly: Service and Repair REMOVAL NOTE: Disconnect the battery negative cable to prevent accidental starter engagement. 1. Remove the cylinder head cover. 2. For rocker arm removal on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke. 3. For rocker arm removal on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke. 4. For rocker arm removal on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke. 5. For rocker arm removal on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke. 6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 45). INSTALLATION CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters. NOTE: Coat the rocker arms with clean engine oil prior to installation. 1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke. 2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke. 3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke. 4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke. 5. Using special tool 8516 press downward on the valve spring, install rocker arm (Fig. 45). 6. Install the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Description and Operation Valve Cover: Description and Operation DESCRIPTION The cylinder head covers are made of die cast magnesium, and are not interchangeable from side-to-side. It is imperative that nothing rest on the cylinder head covers. Prolonged contact with other items may wear a hole in the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation Valve Cover: Service and Repair Removal and Installation REMOVAL - RIGHT SIDE 1. Disconnect battery negative cable. 2. Remove air cleaner assembly, resonator assembly and air inlet hose. 3. Drain cooling system. 4. Remove accessory drive belt. 5. Remove air conditioning compressor retaining bolts and move compressor to the left. 6. Remove heater hoses. 7. Disconnect injector and ignition coil connectors. 8. Disconnect and remove Positive Crankcase Ventilation (PCV) hose. 9. Remove oil fill tube. 10. Un-clip injector and ignition coil harness and move away from cylinder head cover. 11. Remove right rear breather tube and filter assembly. 12. Remove cylinder head cover retaining bolts. 13. Remove cylinder head cover. NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred. REMOVAL - LEFT SIDE 1. Disconnect negative cable from battery. 2. Remove the resonator assemble and air inlet hose. 3. Disconnect injector connectors and un-clip the injector harness. 4. Route injector harness in front of cylinder head cover. 5. Disconnect the left side breather tube and remove the breather tube. 6. Remove the cylinder head cover mounting bolts. 7. Remove cylinder head cover and gasket. NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred. INSTALLATION - RIGHT SIDE CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole In the cylinder head cover. 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location shown in (Fig. 42). 3. Tighten cylinder head cover bolts and double ended studs to 12 Nm (105 in. lbs.). 4. Install right rear breather tube and filter assembly. 5. Connect injector, ignition coil electrical connectors and harness retaining clips. 6. Install the oil fill tube. 7. Install PCV hose. 8. Install heater hoses. 9. Install air conditioning compressor retaining bolts. 10. Install accessory drive belt. 11. Fill Cooling system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation > Page 1428 12. Install air cleaner assembly, resonator assembly and air inlet hose. 13. Connect battery negative cable. INSTALLATION-LEFT SIDE CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the cylinder head cover. Prolonged contact with other objects may wear a hole in the engine cylinder head cover. 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all studs are in the correct location shown in (Fig. 43). 3. Tighten cylinder head cover bolts and double ended studs to 12 Nm (105 in. lbs.). 4. Install left side breather and connect breather tube. 5. Connect injector electrical connectors and injector harness retaining clips. 6. Install the resonator and air inlet hose. 7. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation > Page 1429 Valve Cover: Service and Repair Cleaning and Inspection CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using Special Tool 8516 Rocker Arm Remover, remove the rocker arms and the hydraulic lash adjusters (Fig. 46). 3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from. 4. Apply shop air to the cylinder to hold the valves in place when the spring is removed 5. Remove the camshaft. NOTE: All eight valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring. 6. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed. 7. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor. 8. Remove the valve spring compressor. 9. Remove the spring retainer, and the spring. 10. Remove the valve stem seal. NOTE: The valve stem seals are common between intake and exhaust. INSTALLATION 1. Coat the valve stem with clean engine oil and install the valve stem seal. Make sure the seal is fully seated and that the garter spring at the top of the seal is intact. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1433 2. Install the spring and the spring retainer (Fig. 47). 3. Using Special Tool 8387 Valve Spring Compressor, compress the spring and install the two valve spring retainer halves. 4. Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated. 5. Install the camshaft. 6. Position the hydraulic lash adjusters and rocker arms (Fig. 46). 7. Install the cylinder head cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Stem to Guide Clearance Intake 0.0008 - 0.0028 in Exhaust 0.0019 - 0.0039 in Max. Allowable Stem to Guide Clearance Intake 0.0028 in Exhaust 0.0039 in Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1437 Valve: Service and Repair STANDARD PROCEDURE-REFACING NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 inch). 2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone. 3. When the seat is properly positioned the width of the intake seat must be 1.75 - 2.36 mm (0.0689 - 0.0928 inch) and the exhaust seat must be 1.71 - 2.32 mm (0.0673 - 0.0911 inch). 4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 41.44 mm (1.6315 inch). 5. The valve seat and valve face must maintain a face angle of 44.5 - 45° angle (Fig. 44). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension on the 4.7L engine. These engines are equipped with an automatic belt tensioner (Fig. 4). The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 4.71, engines. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1442 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 17), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 17). 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. ACCESSORY DRIVE BELT DIAGNOSIS CHART PART 1 OF 2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1443 ACCESSORY DRIVE BELT DIAGNOSIS CHART PART 2 OF 2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1444 Drive Belt: Service and Repair REMOVAL CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREE ARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER. Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt tensioner. 1. Disconnect negative battery cable from battery. 2. Rotate belt tensioner until it contacts it's stop. Remove belt, then slowly rotate the tensioner into the free arm position. (Fig. 18). INSTALLATION Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt tensioner. 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 18). 2. Install new belt (Fig. 18). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1445 3. With the drive belt installed, inspect the belt wear indicator (Fig. 19). On 4.7L Engines only, the gap between the tang and the housing stop ( measurement A ) must not exceed 24 mm (0.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Automatic Belt Tensioner to Mounting Bracket Bolts 50 ft.lb Automatic Belt Tensioner to Block Bolts 30 ft.lb Automatic Belt Tensioner Pulley Bolt 45 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1449 Drive Belt Tensioner: Service and Repair REMOVAL On 4.7L engines, the tensioner is equipped with an indexing tang on back of tensioner and an indexing stop on tensioner housing. If a new belt is being installed, tang must be within approximately 24 mm (0.94 inches) of indexing stop. Belt is considered new if it has been used 15 minutes or less. If the above specification cannot be met, check for: The wrong belt being installed (incorrect length/ width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. NOTE: A used belt should be replaced if tensioner indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point. 1. Remove accessory drive belt. 2. Remove tensioner assembly from mounting bracket (Fig. 5). WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER. 3. Remove pulley bolt. Remove pulley from tensioner. INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.) torque. 2. An indexing slot is located on back of tensioner. Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt to 41 Nm (30 ft. lbs.). 3. Install accessory drive belt. 4. Check belt indexing marks (Fig. 4). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Generator Mounting-Bolts M10 Bolts 40 ft.lb M8 Bolts 250 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Mount Bracket to Block Bolts 45 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 FRONT MOUNT REMOVAL 1. Disconnect the negative cable from the battery. CAUTION: Remove the fan blade, fan clutch and fan shroud before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud. 2. Remove the fan blade, fan clutch and fan shroud. 3. Remove the engine oil filter. 4. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan. 5. Remove the four 4 cylinder block-to-insulator mount bolts and the nut from the engine insulator mount through bolt (4x2 Vehicles only) (Fig. 88) (Fig. 89). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1458 6. Remove the three 3 cylinder block-to-insulator mount bolts and loosen the nut from the engine insulator mount through bolt (4x4 Vehicles only) (Fig. 90) (Fig. 91). 7. Using the jack, raise the engine high enough to remove the engine insulator mount through bolt and the insulator mount. INSTALLATION 1. Position the insulator mount and install the insulator mount through bolt. 2. Lower the engine until the four cylinder block-to-insulator mount bolts can be installed. 3. Remove the jack and block of wood. 4. Torque the cylinder block-to-insulator mount bolts to 61 Nm (45 ft. lbs.). 5. Install and torque the through bolt retaining nut to 61 Nm (45 ft. lbs.). 6. Install the fan blade, fan clutch and fan shroud. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1459 Engine Mount: Service and Repair Rear Mount REMOVAL 1. Raise vehicle on hoist. 2. Using a suitable jack, support transmission. 3. Remove the nut from the insulator mount through bolt (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1460 4. Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic transmission only) (Fig. 94). 5. Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). 6. Raise the transmission and remove the bolts retaining the mount to the crossmember (4x4 automatic transmission only) (Fig, 94). 7. Remove the two nuts retaining the isolator to the crossmember (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). 8. Remove the bolts (two bolts manual transmission)(three bolts 4x2 automatic transmission) retaining the insulator bracket to the transmission. INSTALLATION 1. Follow the removal procedure in the reverse order. 2. Tighten the through bolt retaining nut to 101 Nm (75 ft. lbs.). 3. Tighten the isolator bracket to transmission retaining bolts (Manual transmission and 4x2 automatic transmission only) to 68 Nm (50 ft. lbs.). 4. Tighten the mount bracket to transmission retaining bolts (4A automatic transmission only) to 68 Nm (50 ft. lbs.). 5. Tighten the isolator mount to crossmember retaining nuts (Manual transmission and 4x2 automatic transmission only) to 41 Nm (30 ft. lbs.). 6. Tighten the mount bracket to crossmember retaining bolts (4A automatic transmission only) to 28 Nm (250 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 4 psi CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25 - 110 psi Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Locations Engine Oil Dip Stick - Dip Stick Tube: Locations The engine oil level indicator is located at the right rear of the engine on the 4.7L engines. (Fig. 99). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity w/filter .................................................................................................................. ....................................................................... 6.0 Qt Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1475 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ................................... 5W-30 SAE or 10W-30 SAE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1476 Engine Oil: Service Precautions American Petroleum Institute (API) Engine Oil Identification Symbol For best performance and maximum protection for all engines under all types of operation, select only engine oils that meet American Petroleum Institute (API) certification and SAE viscosity standards. This symbol on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1477 Engine Oil: Service and Repair STANDARD PROCEDURE-ENGINE OIL SERVICE WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Daimler Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise (Fig. 100) to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 101) hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 130 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1484 Oil Pan: Service and Repair REMOVAL - 4X2 1. Drain the cooling system. 2. Remove the upper fan shroud. 3. Remove the throttle body resonator and air inlet hose. 4. Remove the intake manifold. 5. Raise vehicle on hoist. 6. Disconnect exhaust pipe at exhaust manifolds. 7. Remove the structural dust cover (Fig. 102) using sequence shown. 8. Drain engine oil and remove oil filter. 9. Position suitable jack under engine. 10. Remove both left and right side engine mount through bolts (Fig. 103). 11. Raise engine to provide clearance to remove oil pan. 12. Place blocks of wood between engine brackets and lower mounts to provide stability to engine. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1485 13. Remove the oil pan mounting bolts and oil pan (Fig. 104). 14. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine. REMOVAL - 4X4 NOTE: 4X4 vehicles equipped with a 4.7L engine must have the front axle removed before the oil pan can be removed. 1. Remove the front axle from vehicle. Refer to TRANSMISSION AND DRIVETRAIN. 2. Remove the structural dust cover (Fig. 105) using sequence shown. 3. Drain the engine oil and remove oil filter. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan. 4. Remove the oil pan mounting bolts and oil pan (Fig. 106). 5. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine. INSTALLATION - 4X2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1486 1. Clean the oil pan gasket mating surface of the bedplate and oil pan. 2. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 Nm (20 ft. lbs.). 3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 104). 4. Raise the engine and remove the blocks of wood. 5. Lower engine and install both the left and right side engine mount through bolts (Fig. 103). Tighten the nuts to 68 Nm (50 ft. lbs.). 6. Remove jack and install oil filter. 7. Install structural dust cover. 8. Install exhaust pipe onto exhaust manifolds. 9. Lower vehicle. 10. Install intake manifold. 11. Install throttle body resonator and air inlet hose. 12. Install upper fan shroud. 13. Fill cooling system. 14. Fill engine oil. 15. Start engine and check for leaks. INSTALLATION - 4X4 1. Clean the oil pan gasket mating surface of the bedplate and oil pan. 2. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 Nm (20 ft. lbs.). 3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 106). 4. Install structural dust cover. 5. Install oil filter. 6. Install front axle. Refer to TRANSMISSION AND DRIVETRAIN. 7. Lower vehicle. 8. Fill engine oil. 9. Start engine check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations > Page 1490 Oil Pressure Gauge: Description and Operation OIL PRESSURE GAUGE An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication about forty seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1494 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1495 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1496 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine oil pressure .............................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pickup Tube Bolt and Nut 250 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 4 psi CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25 - 110 psi Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications Tighten intake manifold retaining bolts in sequence shown to 12 Nm (105 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1511 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .............................................................................................................................................................. 12 Nm (105 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1512 Intake Manifold: Description and Operation DESCRIPTION The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Eight studs and two bolts are used to fasten the intake to the head. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1513 Intake Manifold: Testing and Inspection DIAGNOSIS AND TESTING-INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water at the suspected leak area. 3. If a change in RPM is observed the area of the suspected leak has been found. 4. Repair as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Intake Manifold: Service and Repair Intake Manifold REMOVAL 1. Disconnect negative cable from battery. 2. Remove resonator assembly and air inlet hose. 3. Disconnect throttle and speed control cables. 4. Disconnect electrical connectors for the following components: - Manifold Absolute Pressure (MAP) Sensor - Intake Air Temperature (IAT) Sensor - Throttle Position (TPS) Sensor - Coolant Temperature (CTS) Sensor - Idle Air Control (IAC) Motor 5. Disconnect brake booster hose and Positive Crankcase Ventilation (PCV) hose. 6. Disconnect generator electrical connections. 7. Disconnect air conditioning compressor electrical connections. 8. Disconnect left and right radio suppressor straps. 9. Disconnect and remove ignition coil towers. 10. Remove top oil dipstick tube retaining bolt and ground strap. 11. Bleed fuel system. 12. Remove fuel rail. 13. Remove throttle body assembly and mounting bracket. 14. Drain cooling system below coolant temperature level. 15. Remove the heater hoses from the engine front cover and the heater core. 16. Unclip and remove heater hoses and tubes from intake manifold (Fig. 115). 17. Remove coolant temperature sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1516 18. Remove intake manifold retaining fasteners in reverse order of tightening sequence (Fig. 116). 19. Remove intake manifold. INSTALLATION 1. Install intake manifold gaskets. 2. Position intake manifold. 3. Install intake manifold retaining bolts and tighten in sequence shown in (Fig. 117) to 12 Nm (105 in. lbs.). 4. Install left and right radio suppressor straps. 5. Install throttle body assembly. 6. Install throttle cable bracket. 7. Connect throttle cable and speed control cable to throttle body. 8. Install fuel rail. 9. Install ignition coil towers. 10. Position and install heater hoses and tubes onto intake manifold. 11. Install the heater hoses to the heater core and engine front cover. 12. Connect electrical connectors for the following components: - Manifold Absolute Pressure (MAP) Sensor - Intake Air Temperature (IAT) Sensor - Throttle Position (TPS) Sensor - Coolant Temperature (CTS) Sensor - Idle Air Control (IAC) Motor - Ignition coil towers - Fuel injectors 13. Install top oil dipstick tube retaining bolt and ground strap. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1517 14. Connect generator electrical connections. 15. Connect Brake booster hose and Positive Crankcase Ventilation (PCV) hose. 16. Fill cooling system. 17. Install resonator assembly and air inlet hose. 18. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1518 Intake Manifold: Service and Repair Cleaning and Inspection CLEANING NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced. Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry. INSPECTION 1. Inspect the intake sealing surface for cracks, nicks and distortion. 2. Inspect the intake manifold vacuum hose fittings for looseness or blockage. 3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations > Page 1523 Oil Pressure Gauge: Description and Operation OIL PRESSURE GAUGE An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication about forty seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine oil pressure .............................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection Crankshaft Main Bearing Seal: Testing and Inspection DIAGNOSIS AND TESTING-REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See Engine, for proper repair procedures of these items. 4. If no leaks are detected, pressurized the crankcase, Inspection (Engine oil Leaks in general) CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. 7. After the oil leak root cause and appropriate corrective action have been identified. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1531 Crankshaft Main Bearing Seal: Service and Repair REMOVAL NOTE: This procedure can be performed in vehicle. 1. If being performed in vehicle, remove the transmission. 2. Remove the flexplate. NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine. 3. Using Special Tool 8506 (Fig. 68), remove the crankshaft rear oil seal. INSTALLATION 1. Position the magnetic seal guide Special Tool 8349-2 (Fig. 69) onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1532 2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle (Fig. 70), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore. 3. Install the flexplate. 4. If removed, install the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Remove A/C compressor mounting fasteners and set aside. 4. Drain cooling system. 5. Remove upper radiator hose. 6. Disconnect electrical connector for fan mounted inside radiator shroud. 7. Remove radiator shroud attaching fasteners. NOTE: Transmission cooler line snaps into shroud lower right hand corner. 8. Remove radiator cooling fan and shroud. 9. Remove crankshaft damper bolt. 10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller (Fig. 65). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1536 11. Using Special Tool 8511, remove crankshaft front seal (Fig. 66). INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Using Special Tool 8348 and 8512, install crankshaft front seal (Fig. 67). 2. Install vibration damper. 3. Install radiator cooling fan and shroud. 4. Install upper radiator hose. 5. Install A/C compressor and tighten fasteners to 54 Nm (40 ft. lbs.). 6. Install accessory drive belt refer. 7. Refill cooling system. 8. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1541 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1542 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1543 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Bolt 130 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Crankshaft Damper Bolt 130 ft.lb Timing Chain Cover Bolts 40 ft.lb Timing Chain Guide Bolts 250 in.lb Timing Chain Tensioner Arm - Special Pin Bolt 150 in.lb Hydraulic Tensioner Bolts 250 in.lb Timing Chain Primary Tensioner Bolts 250 in.lb Timing Drive Idler Sprocket Bolt 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1554 Timing Chain: Testing and Inspection STANDARD PROCEDURE-MEASURING TIMING CHAIN WEAR NOTE: This procedure must be performed with the timing chain cover removed. 1. Remove the timing chain cover. 2. To determine if the secondary timing chains are worn, rotate the engine clockwise until maximum tensioner piston extension is obtained. Measure the distance between the secondary timing chain tensioner housing and the step ledge on the piston (Fig. 123). The measurement at point (A) must be less than 15 mm (0.5906 inches). 3. If the measurement exceeds the specification the secondary timing chains are worn and require replacement. NOTE: If the secondary chains are to be replaced the primary chain must also be replaced. INSPECTION Inspect the following components: Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. - Idler sprocket assembly bushing and shaft for excessive wear. - Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement. - Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 mm (0.039 inch) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced. - secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner and tensioner arm should be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1555 - Primary chain tensioner plastic faces. Replace as required (Fig. 140). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1556 Timing Chain: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Remove right and left cylinder head covers. 4. Remove radiator fan shroud. 5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (# 1 cylinder exhaust stroke) and the camshaft sprocket "V8" marks are at the 12 o'clock position. 6. Remove power steering pump. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1557 7. Remove access plugs from left and right cylinder heads for access to chain guide fasteners. 8. Remove the oil fill housing to gain access to the right side tensioner arm fastener. 9. Remove crankshaft damper and timing chain cover. 10. Collapse and pin primary chain tensioner. CAUTION: Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening. 11. Remove secondary chain tensioners. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1558 12. Remove camshaft position sensor from right cylinder head (Fig. 137). CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition. CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement. 13. Remove left and right camshaft sprocket bolts. 14. While holding the left camshaft steel tube with adjustable pliers, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 15° clockwise to a neutral position. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1559 15. While holding the right camshaft steel tube with adjustable pliers, remove the right camshaft sprocket. Slowly rotate the camshaft approximately 45 degrees counterclockwise to a neutral position. 16. Remove idler sprocket assembly bolt. 17. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains. 18. Remove both pivoting tensioner arms and chain guides. 19. Remove chain tensioner. INSPECTION Inspect the following components: Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. - Idler sprocket assembly bushing and shaft for excessive wear. - Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement. - Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 min (0.039 inch) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced. - secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner and tensioner arm should be replaced. - Primary chain tensioner plastic faces. Replace as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1560 INSTALLATION 1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1561 Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin. 2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 Nm (250 in. lbs.). CAUTION: Over tightening the tensioner arm torx bolt can cause severe damage to the cylinder head. Tighten torx bolt to specified torque only. 3. Install right side chain tensioner arm. Apply Mopar Lock N Seal to torx bolt, tighten bolt to 17 Nm (150 in. lbs.). NOTE: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block. 4. Install the left side chain guide. Tighten the bolts to 28 Nm (250 in. lbs.). CAUTION: Over tightening the tensioner arm torx8 bolt can cause severe damage to the cylinder head. Tighten torx bolt to specified torque only. 5. Install left side chain tensioner arm. Apply Mopar Lock N, Seal to torx bolt, tighten bolt to 17 Nm (150 in. lbs.). 6. Install the right side chain guide. Tighten the bolts to 28 Nm (250 in. lbs.). 7. Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o'clock and 8 o'clock). Once the secondary timing chains are installed, position special tool 8515 to hold chains in place for installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1562 8. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 O'clock on the crankshaft sprocket. 9. Lubricate idler shaft and bushings with clean engine oil. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1563 10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. After gliding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation. NOTE: It will be necessary to slightly rotate camshafts for sprocket installation. 11. Align left camshaft sprocket "L" dot to plated link on chain. 12. Align right camshaft sprocket "R" dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over torque of bolt resulting in bolt failure. 13. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1564 14. Verify that all plated links are aligned with the marks on all sprockets and the "V8" marks on camshaft sprockets are at the 12 o'clock position. CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed. 15. Install both secondary chain tensioners. Tighten bolts to 28 Nm (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common. 16. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 Nm (25 ft. lbs.) . 17. Remove all locking pins (3) from tensioners. CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1565 18. Using Special Tool 6958, Spanner with Adapter Pins 8346, tighten left and right camshaft sprocket bolts to 122 Nm (90 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1566 19. Rotate engine two full revolutions. Verify timing marks are at the follow locations: - primary chain idler sprocket dot is at 12 o'clock - primary chain crankshaft sprocket dot is at 6 o'clock - secondary chain camshaft sprockets "V8" marks are at 12 o'clock 20. Lubricate all three chains with engine oil. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1567 21. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10 - 0.25 mm (0.004 - 0.010 inch). If not within specification, the idler gear must be replaced. 22. Install timing chain cover and crankshaft damper. 23. Install cylinder head covers. NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks. 24. Coat the large threaded access plug with Mopar Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 Nm (60 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1568 25. Install the oil fill housing. 26. Install access plug in left cylinder head. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1569 27. Install power steering pump. 28. Install radiator fan shroud. 29. Fill cooling system. 30. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Bolts 250 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Idler Gear > Component Information > Specifications Timing Chain Idler Gear: Specifications Timing Drive Idler Sprocket Bolt 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications 4.7 4.7 Timing Chain Tensioner Arm - Special Pin Bolt 150 in.lb Hydraulic Tensioner Bolts 250 in.lb Timing Chain Primary Tensioner Bolts 250 in.lb Timing Drive Idler Sprocket Bolt 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > Page 1582 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Cover Bolts 40 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 1603 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1604 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1609 right front side of the engine block (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1610 Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service Precautions Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Torque ................................................................................................................................................. ....................................................... 27 Nm (20 ft. lbs) Plug Type ............................................................................................................................................ .............................................................. RC12MCC4 Electrode Gap ...................................................................................................................................... ................................................... 1.01 mm (0.040 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1621 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1622 Spark Plug: Description and Operation All engines use resistor type spark plugs. This engine is equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1623 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig.28 Normal Operation And Cold (Carbon) Fouling Normal Operating The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. On all engines except the 4.7L V-8, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. On the 4.7L V-8, gap growth will not average more than approximately 0.0015 in per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1624 Fig.29 Oil Or Ash Encrusted Oil or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.30 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1625 Fig.31 Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig.32 Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1626 Fig.33 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig.34 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1627 Spark Plug: Service and Repair REMOVAL Fig.35 Heat Shields - 3.9/5.2/5.9L Engines On 3.9L V-6 and 5.2/5.9L V-8 engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 4.7L V-8 Engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. Except 4.7L Engine: Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. 4.7L V-8 Engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 3. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition of coil O-ring and replace as necessary. Fig.37 Cable Removal 4. Except 4.7L: Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 5. Inspect spark plug condition. Refer to Spark Plug Conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1628 CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: The 4.7L V-8 engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. Except 4.7L Engine: When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Except 4.7L Engine: Tighten spark plugs to 35 - 41 Nm (26-30 ft. lbs.) torque. 3. Except 4.7L Engine: Install spark plug cables over spark plugs. 4. 4.7L V-8 Engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 5. 4.7L V-8 Engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 6. 4.7L V-8 Engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1632 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 40 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1639 Water Pump: Description and Operation DESCRIPTION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley. DESCRIPTION-WATER PUMP BYPASS Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1640 The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat uses a stub shaft located at the rear of the thermostat to control flow through the bypass gallery. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. OPERATION-WATER PUMP BYPASS When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the stub shaft enters the bypass gallery obstructing bypass coolant flow by 50%. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1641 Water Pump: Service and Repair REMOVAL The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Remove fan/viscous fan drive assembly from water pump. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the torque of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1642 5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector. 6. Remove upper fan shroud and fan blade/viscous fan drive assembly from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 8. Remove accessory drive belt. 9. Remove lower radiator hose clamp and remove lower hose at water pump. 10. Remove seven water pump mounting bolts and one stud bolt. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 11. Remove water pump and gasket. Discard gasket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1643 CLEANING Clean the gasket mating surface. Use caution riot to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. INSTALLATION The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Clean gasket mating surfaces. 2. Using a new gasket, position water pump and install mounting bolts as shown. Tighten water pump mounting bolts to 54 Nm (40 ft. lbs.) torque. 3. Spin water Pump to be sure that pump impeller does not rub against timing chain case/cover. 4. Connect radiator lower hose to water pump. 5. Relax tension from belt tensioner. Install drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1644 CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. 6. Position upper fan shroud and fan blade/viscous fan drive assembly. 7. Be sure the upper and lower portions of the fan shroud are firmly connected. All air must flow through the radiator. 8. Install two fan shroud-to-radiator screws. 9. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud. 10. Install fan blade/viscous fan drive assembly to water pump shaft. 11. Fill cooling system. 12. Connect negative battery cable. 13. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .......................................... 12.3 Liters ( 13.0 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1650 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1651 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Locations Coolant Level Indicator Lamp: Locations The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Locations > Page 1655 Coolant Level Indicator Lamp: Description and Operation COOLANT LOW INDICATOR The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. The coolant low indicator consists of a stenciled cutout of the words "LOW COOLANT" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "LOW COOLANT" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The coolant low indicator is serviced as a unit with the instrument cluster. The coolant low indicator gives an indication to the vehicle operator when the engine coolant level is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface PCI data bus. The coolant low indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the coolant low indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the coolant low indicator is illuminated for about two seconds as a bulb test. - Coolant Low Lamp-ON Message - Each time the cluster receives a message from the PCM indicating the engine coolant level is low, the coolant low indicator will be illuminated, and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine coolant level is not low, 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 coolant low indicator is cycled OFF and then ON again by the appropriate lamp-OFF and lamp-ON messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant level through the low coolant level switch, then sends the proper messages to the instrument cluster. For further diagnosis of the coolant low indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the low coolant level switch, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the coolant low indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL WITHOUT AIR CONDITIONING 1. Partially drain cooling system.Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. WITH AIR CONDITIONING Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 1659 If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. 1. Disconnect battery negative cable. 2. Partially drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body cables. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 1660 13. Remove six bracket bolts. 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION WITHOUT AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. WITH AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2- to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Install drive belt. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. 16. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation COOLANT RECOVERY CONTAINER DESCRIPTION The coolant recovery container is integral to the upper fan shroud assembly and is made of high temperature plastic OPERATION The coolant recovery container works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 1664 Coolant Reservoir: Service and Repair NOTE: The coolant reservoir/overflow tank is integral to the upper fan shroud. Refer to Fan Shroud, Service and Repair for proper removal/installation procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Radiator Fan Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1687 Radiator Cooling Fan Motor: Description and Operation RADIATOR FAN ELECTRIC DESCRIPTION The fan is electrically controlled by the Powertrain Control Module (PCM) through the fan control relay. This relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to label on PDC cover. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM regulates fan operation based on input from the engine coolant temperature sensor, battery temperature sensor,air conditioning select switch and vehicle speed. The fan is not energized during engine cranking regardless of the electrical input from the temperature sensors and air conditioning switch. However, if engine operation conditions warrant fan engagement, the fan will run once engine starts. On vehicles NOT equipped with AC: The relay is energized when the coolant temperature is above 80°C (176°F), or battery temperature sensor above -12°C (10°F). It will then de-energize when coolant temperature drops below 82°C (180°F), or batter temperature sensor below - 9°C (16°F). Vehicles Equipped with AC: In addition to using coolant temperature and battery temperature sensor to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system is activated. The relay is also energized when, air conditioning is selected and coolant temperature is above 95°C (203°F), or, air conditioning is selected and battery temperature sensor is above 41°C (106°F). It will then de-energize when, air conditioning is selected and coolant temperature is below 92°C (198°F), or, air conditioning is selected and battery temperature is below 38° C (100°F). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1688 Radiator Cooling Fan Motor: Testing and Inspection ELECTRIC COOLING FAN The Powertrain Control Module (PCM) will set a Diagnostic Trouble Code (DTC) in memory if it detects a problem in the electric cooling fan , relay or circuit. The DTC can also be accessed through the DRB scan tool. RADIATOR FAN MOTOR INOPERATIVE Equipment Required: ^ DRB Scan Tool ^ Volt/Ohm meter ^ Wiring Diagrams Test Procedure: 1. Inspect 10A fuse in junction block and 40A maxi fuse in PDC. 2. Remove Cooling Fan Relay from the PDC and make the following checks at the relay connector: ^ Apply 12 volts (using a fused 14-gauge wire) to circuit C25 (relay terminal 87). If fan does not come on, check for open in circuit C25 or Z1. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1689 If circuits are o.k, replace the cooling fan motor. ^ With the ignition key "off" check for battery voltage at circuit C28 (relay terminal 30). If no battery voltage present check for open/shorted circuit C28 between the PDC and relay. ^ With the ignition key in the "run" position check for battery voltage at circuit F18 (relay terminal 86). If no battery voltage present, check for open/short in circuit F18 between the junction block and the relay. ^ If no problems are detected, install the DRB and start the engine. Clip a 12V test light to the battery positive terminal and probe circuit C27 (relay terminal 85). When the engine temperature reaches 110°C (230°F), or A/C is requested, the test light should light. If not, check circuit C27 for open. ^ If no problems are detected at this point, replace the cooling fan relay. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1690 Radiator Cooling Fan Motor: Service and Repair REMOVAL If the fan blade is bent, warped, cracked or damaged in any way, it must be replaced only with a replacement fan blade. Do not attempt to repair a damaged fan blade. 1. Disconnect battery negative cable. 2. Disconnect fan motor wire connector. 3. Remove the two fan shroud mounting clips connecting the upper part of fan shroud to the radiator. 4. Remove fan assembly from radiator. INSTALLATION 1. Install fan assembly onto the radiator. Tighten bolts 5 Nm (45 inch lbs.). 2. Connect fan motor wire connector to harness connector. 3. Connect battery negative cable. 4. Start engine and check fan operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1694 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1695 Radiator Cooling Fan Motor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1696 Radiator Fan Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1697 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection Fan Blade: Testing and Inspection INSPECTION WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. 1. Remove fan blade assembly from viscous fan drive unit (four bolts). 2. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (0.090 inch). Test all blades in this manner. 3. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Page 1701 Fan Blade: Service and Repair RADIATOR FAN VISCOUS CLEANING Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1706 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1707 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1708 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1709 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Mounting Bolts 50 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1716 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1717 Heater Core: Description and Operation The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1718 Heater Core: Service and Repair REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Drain to cooling systems. 2. Remove the heater-A/C housing from the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 3. Disassemble the HVAC housing to access the heater core. 4. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble the heater-A/C housing. 3. Install the heater-A/C housing into the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 4. Refill the cooling system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Locations Coolant Level Indicator Lamp: Locations The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Locations > Page 1723 Coolant Level Indicator Lamp: Description and Operation COOLANT LOW INDICATOR The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. The coolant low indicator consists of a stenciled cutout of the words "LOW COOLANT" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "LOW COOLANT" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The coolant low indicator is serviced as a unit with the instrument cluster. The coolant low indicator gives an indication to the vehicle operator when the engine coolant level is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface PCI data bus. The coolant low indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the coolant low indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the coolant low indicator is illuminated for about two seconds as a bulb test. - Coolant Low Lamp-ON Message - Each time the cluster receives a message from the PCM indicating the engine coolant level is low, the coolant low indicator will be illuminated, and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine coolant level is not low, 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 coolant low indicator is cycled OFF and then ON again by the appropriate lamp-OFF and lamp-ON messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant level through the low coolant level switch, then sends the proper messages to the instrument cluster. For further diagnosis of the coolant low indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the low coolant level switch, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the coolant low indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 1727 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to- right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 129 °C (264 °F)], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (252 °F), the gauge needle is moved into the red zone on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 122 °C (252 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate engine temperature messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about forty seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications Radiator to Support Bolts 200 in.lb Upper Radiator Closure Panel Bolts 90 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1731 Radiator: Description and Operation DESCRIPTION The radiator is an aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine and automatic transmission oil (if equipped). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1732 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through cooling system. 1. Idle engine until operating temperature is reached. If upper radiator hose is warm to the touch, thermostat is opening and coolant is flowing to radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO FIRST STOP. ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/ OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK. 2. Drain a small amount of coolant from radiator until ends of radiator tubes are visible through filler neck. Idle engine at normal operating temperature. If coolant is flowing past exposed tubes, coolant is circulating. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1733 Radiator: Service and Repair REMOVAL WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Disconnect battery negative cable. 2. Drain cooling system. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 3. Remove hose clamps and hoses from radiator. Disconnect coolant reserve/overflow tank hose and washer bottle electrical connector and hose. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1734 4. Remove upper fan shroud mounting screws Lift upper fan shroud assembly up and out of engine compartment. 5. Disconnect transmission oil cooler lines, (if equipped). 6. Disconnect electric cooling fan motor connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1735 7. Remove radiator upper mounting screws. Lift radiator upward and away from vehicle. Do not allow cooling fins of radiator to contact any other vehicle component. Radiator fin damage could result. CLEANING Clean radiator fins with the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris. INSPECTION The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks. Inspect the radiator neck for damage or distortion. INSTALLATION The radiator has two isolator pins on bottom of both tanks. These fit into alignment holes in radiator lower support. 1. Position isolator pins into alignment holes in radiator lower support. 2. Install and tighten radiator mounting bolts to 23 Nm (200 inch lbs.). 3. Install the transmission oil cooler lines, (if equipped). 4. Connect fan motor electrical connector to harness connector. 5. Position upper fan shroud onto lower fan shroud and radiator. 6. Install retaining screws into shroud. 7. Install radiator hoses. reconnect coolant reserve/overflow tank hose. 8. Connect battery negative cable. 9. Fill cooling system. 10. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation DESCRIPTION All cooling systems are equipped with a pressure cap in the radiator upper hose. This cap releases pressure at some point within a range of 131-to-158 kPa (l9-to-23 psi). The pressure relief point (in pounds) is engraved on top of the cap. The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring loaded pressure relief valve. This valve opens when system pressure reaches the release range of 131-to 158 kPa (l9-to-23 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse on cool-down. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1741 Radiator Cap: Component Tests and General Diagnostics Cooling System Pressure Relief Testing RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 131 kPa (21 psi) and hold pressure at a minimum of 130 kPa (18.8 psi). WARNING: THE WARNING WORDS -DO NOT OPEN HOT-ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove radiator cap at any time except for the following purposes: 1. Check and adjust antifreeze freeze point. 2. Refill system with new antifreeze. 3. Conducting service procedures. 4. Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTERCLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/ OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. Radiator Cap Testing RADIATOR CAP Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring pressure to 138 kPa (20 psi) on gauge. If pressure cap fails to hold pressure of at least 131 kPa (19 psi) replace cap. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1742 Radiator Cap: Service and Repair RADIATOR PRESSURE CAP CLEANING Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage to the seal in the radiator cap. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1747 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1748 Radiator Cooling Fan Motor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1749 Radiator Fan Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1750 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1756 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1757 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1758 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1759 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 1763 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to- right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 129 °C (264 °F)], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (252 °F), the gauge needle is moved into the red zone on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 122 °C (252 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate engine temperature messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about forty seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications On all engines the thermostat is closed below 195°F (90°C). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1767 Thermostat: Description and Operation ENGINE COOLANT THERMOSTAT DESCRIPTION CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1768 A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control and. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation. OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1769 Thermostat: Testing and Inspection THERMOSTAT ON-BOARD DIAGNOSTICS All gasoline powered models are equipped with On-Board Diagnostics for certain cooling system components. 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 DRB scan tool. Refer to the appropriate Diagnostic Procedures information for diagnostic information and operation of the DRB scan tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1770 Thermostat: Service and Repair REMOVAL WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. 1. Disconnect negative battery cable at battery. 2. Drain cooling system. 3. Raise vehicle on hoist. 4. Remove splash shield. 5. Remove lower radiator hose clamp and lower radiator hose at thermostat housing. 6. Remove thermostat housing mounting bolts, thermostat housing and thermostat. INSTALLATION 1. Clean mating areas of timing chain cover and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on timing chain cover. 3. Position thermostat housing on timing chain cover. 4. Install two housing-to-timing chain cover bolts. Tighten bolts to 13 Nm (112 inch lbs.) torque. CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks. 5. Install lower radiator hose on thermostat housing. 6. Install splash shield. 7. Lower vehicle. 8. Fill cooling system. 9. Connect negative battery cable to battery. 10. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolts 115 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1774 Thermostat Housing: Service and Repair REMOVAL WITHOUT AIR CONDITIONING 1. Partially drain cooling system.Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the torque of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. WITH AIR CONDITIONING Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1775 If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. 1. Disconnect battery negative cable. 2. Partially drain cooling system.Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body cables. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube, 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1776 13. Remove six bracket bolts. 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION WITHOUT AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. WITH AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2- to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Install drive belt. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. 16. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 40 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1780 Water Pump: Description and Operation DESCRIPTION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley. DESCRIPTION-WATER PUMP BYPASS Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1781 The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat uses a stub shaft located at the rear of the thermostat to control flow through the bypass gallery. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. OPERATION-WATER PUMP BYPASS When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the stub shaft enters the bypass gallery obstructing bypass coolant flow by 50%. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1782 Water Pump: Service and Repair REMOVAL The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Remove fan/viscous fan drive assembly from water pump. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the torque of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1783 5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector. 6. Remove upper fan shroud and fan blade/viscous fan drive assembly from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 8. Remove accessory drive belt. 9. Remove lower radiator hose clamp and remove lower hose at water pump. 10. Remove seven water pump mounting bolts and one stud bolt. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 11. Remove water pump and gasket. Discard gasket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1784 CLEANING Clean the gasket mating surface. Use caution riot to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. INSTALLATION The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Clean gasket mating surfaces. 2. Using a new gasket, position water pump and install mounting bolts as shown. Tighten water pump mounting bolts to 54 Nm (40 ft. lbs.) torque. 3. Spin water Pump to be sure that pump impeller does not rub against timing chain case/cover. 4. Connect radiator lower hose to water pump. 5. Relax tension from belt tensioner. Install drive belt. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1785 CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. 6. Position upper fan shroud and fan blade/viscous fan drive assembly. 7. Be sure the upper and lower portions of the fan shroud are firmly connected. All air must flow through the radiator. 8. Install two fan shroud-to-radiator screws. 9. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud. 10. Install fan blade/viscous fan drive assembly to water pump shaft. 11. Fill cooling system. 12. Connect negative battery cable. 13. Start and warm the engine. Check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 18 ft.lb Tighten all manifold bolts starting at center and working outward. Exhaust Manifold Heat Shield Nuts 72 in.lb Then loosen 45 degrees Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1790 Exhaust Manifold: Description and Operation DESCRIPTION The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL RIGHT EXHAUST MANIFOLD 1. Disconnect negative cable for battery. 2. Remove air cleaner assembly, resonator assembly and air inlet hose. 3. Remove accessory drive belt. 4. Remove A/C compressor. 5. Remove A/C accumulator support bracket fastener. 6. Drain coolant below heater hose level. 7. Remove heater hoses at engine. 8. Remove fasteners attaching exhaust manifold heat shield. 9. Remove heat shield. 10. Remove upper exhaust manifold attaching fasteners. 11. Raise vehicle on hoist. 12. Disconnect exhaust pipe from manifold. 13. Remove fasteners attaching starter. Move starter aside. 14. Remove lower exhaust manifold attaching fasteners. 15. Remove exhaust manifold and gasket. Manifold is removed from below the engine compartment. LEFT EXHAUST MANIFOLD 1. Disconnect negative cable for battery. 2. Hoist vehicle. 3. Disconnect exhaust pipe at manifold. 4. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1793 5. Remove the front two exhaust heat shield retaining fasteners. Raise vehicle and remove the fasteners at rear of heat shield. 6. Remove heat shield. 7. Lower vehicle and remove the upper exhaust manifold retaining bolts. 8. Raise vehicle and remove the lower exhaust manifold retaining bolts. 9. Remove exhaust manifold and gasket. Manifold is removed from below the engine compartment. INSTALLATION RIGHT EXHAUST MANIFOLD Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1794 1. Install exhaust manifold and gasket from below engine compartment. 2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place. 3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 Nm (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack. 4. Install exhaust manifold heat shield. Tighten fasteners to 8 Nm (72 inch lbs.), then loosen 45°. 5. Install starter and fasteners. 6. Connect exhaust pipe to manifold. 7. Connect heater hoses at engine. 8. Install fastener attaching A/C accumulator. 9. Install A/C compressor and fasteners. 10. Install accessory drive belt. 11. Install air cleaner assembly, resonator assembly and air inlet hose. 12. Install battery and connect cables. 13. Fill cooling system. LEFT EXHAUST MANIFOLD 1. Install exhaust manifold and gasket from below engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1795 2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place. 3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 Nm (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack. 4. Install exhaust manifold heat shield. Tighten fasteners to 8 Nm (72 inch lbs.), then loosen 45°. 5. Connect exhaust pipe to manifold. 6. Connect negative cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1796 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING 1. Clean the exhaust manifold using a suitable cleaning solvent, then allow to air dry. 2. Clean all gasket residue from the manifold mating surface. INSPECTION 1. Inspect the exhaust manifold for cracks in the mating surface and at every mounting bolt hole. 2. Using a straight edge and a feeler gauge, check the mating surface for warp and twist. 3. Inspect the manifold to exhaust pipe mating surface for cracks, gouges, or other damage that would prevent sealing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Exhaust Clamp Exhaust Pipe: Specifications Exhaust-Clamps Nuts 30 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Exhaust Clamp > Page 1801 Exhaust Pipe: Specifications Exhaust Pipe To Manifold Nuts 19 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1802 Exhaust Pipe: Description and Operation DESCRIPTION The tailpipe is made of stainless steel and attaches to the muffler. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe REMOVAL CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Disconnect the oxygen sensor(s). 4. Remove the exhaust manifold-to-exhaust pipe nuts. 5. Remove exhaust pipe to converter exhaust clamp. 6. Disconnect the exhaust pipe from the catalytic converter front flange. 7. Remove the exhaust pipe. INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. INSTALLATION 1. Connect the exhaust pipe(s) to the exhaust manifold. Tighten the nuts to 26 Nm (19 ft. lbs.) torque. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1805 2. Align and connect the exhaust pipe to the catalytic converter flange. Install exhaust clamp and tighten clamp nuts to 41 Nm (33 ft. lbs.) torque. 3. Connect oxygen sensor connector(s). 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1806 Exhaust Pipe: Service and Repair Intermediate Pipe INTERMEDIATE PIPE REMOVAL 1. Raise and support the vehicle. 2. Saturate the clamp nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Remove the front and rear clamp nuts. 4. It may be necessary to loosen other sections of the exhaust system to remove the extension pipe. INSTALLATION 1. Position the extension pipe in the muffler and the catalytic converter flange. 2. If other sections of the exhaust system where loosened in removal, refer to the tightening procedures. 3. Install the clamps and nuts. Tighten the nuts to 47 Nm (35 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1807 Exhaust Pipe: Service and Repair Tailpipe REMOVAL CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the clamp nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Remove muffler to tailpipe exhaust clamp. 4. Remove the tailpipe from the front and rear insulators. 5. Remove the tailpipe. INSTALLATION CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Position the tailpipe into the muffler. Install the nuts onto the clamp bolt finger tight. 2. Install the tailpipe into the insulators. 3. Position tailpipe and tighten the muffler rear clamp nuts to 47 Nm (35 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications > Muffler Hanger Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger Screws 16 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications > Muffler Hanger > Page 1812 Exhaust Pipe/Muffler Hanger: Specifications Tail Pipe Hanger Tail Pipe Hanger .................................................................................................................................. ..................................................... 22 Nm (16 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Exhaust Manifold Heat Shield Nuts 72 in.lb Then loosen 45 degrees Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1816 Heat Shield: Description and Operation DESCRIPTION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1817 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1818 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1819 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1820 Heat Shield: Service and Repair REMOVAL 1. Raise and support the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1821 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1822 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1823 2. Remove the screws and/or nuts holding the heat shields to the frame and/or floor pan. 3. When removing muffler heat shield, the muffler front support bracket must be removed first. 4. Slide the shields out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and/or nuts. 2. Tighten the nuts and/or screws to specification. 3. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation Muffler: Description and Operation DESCRIPTION All engines use a stainless steel muffler to control exhaust noise levels and exhaust back pressure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation > Page 1827 Muffler: Service and Repair REMOVAL CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the clamp nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Remove the muffler clamp nuts from the front hanger and the rear muffler to tailpipe connection. 4. Disconnect the muffler from the tailpipe. The tailpipe should be supported when the muffler is disconnected. 5. Remove the muffler from the extension pipe or catalytic converter flange. INSTALLATION CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. If the upper front muffler support was removed, install the bolts into the frame. Tighten the bolts to 23 Nm (200 inch lbs.) torque. The insulators slip over the ends of the upper and lower muffler hangers. 2. Install the muffler into the extension pipe or catalytic converter flange. Install the clamp and tighten the nuts finger tight. 3. Install the tailpipe into the rear of the muffler. 4. Tighten the clamp nuts on the front and rear muffler hangers to 41 Nm (30 ft. lbs.) torque. 5. Lower the vehicle. 6. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations Central Timer Module ( CTM ) High Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 1834 Central Timer Module ( CTM ) High Option: Diagrams Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 1835 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 1836 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information DANGER!!! ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection and remove any metal jewelry, such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 1839 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "lock" position. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the Miller tool #8815 (not the wire end or terminal) in the connector. Do not probe a wire through the insulation; this will damage the wire and eventually cause the wire to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description Central Timer Module ( CTM ) High Option: Description and Operation System Description SYSTEM DESCRIPTION The body system on the Dakota (AN) and Dakota Quad Cab (AN84) consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1842 Central Timer Module ( CTM ) High Option: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/ Mechanical Instrument Cluster (EMIC and CTM) from the ACM via the PCI bus. The AIRBAG warning lamp and chime are the only point at which "symptoms" of a system malfunction can be observed by the customer. When- ever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF; there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Passenger Side Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. 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. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. SPECIAL TOOLS Some airbag diagnostic test use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver and Passenger Airbag, clockspring, or seat belt tensioner (use a jumper if needed). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1843 Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective components has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed squib wiring can be tested for open and shorted conditions. SEAT BELT TENSIONER Front seat belt systems incorporate Seat Belt Tensioner (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1844 remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Central Timer Module CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) - Horn Chirp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1845 - Optical Chirp The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. Chime System CHIME SYSTEM The chime system is built into the CTM. There are two chime rates - Low: 50 chimes per minute for reminders, and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left ON. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light ON the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Ignition OFF, cargo lights ON, drivers door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning (if vehicle speed>0) - Transmission temperature lamp - Turn signal ON reminder warning - Button pushed on compass mini-trip computer (reset) - ABS light ON - Over speed warning GULF COAST COUNTRY (GCC only) - Water in fuel (diesel) Compass/Mini-Trip Computer (CMTC) COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (Miles Per Gallon) or 1/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or 1/100 Km. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions and a chime will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1846 the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly OFF of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Head-lamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. Enhanced Accident Response ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Exterior Lighting EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition Off while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF, The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON, the delay will be canceled and the headlamps will turn OFF immediately. During the delay period, only the headlamps are turned ON and the park lamps/fog lamps are turned OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1847 The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned OFF and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. A 15 minute timeout is initiated if the ignition is OFF and the headlamp switch is cycled from OFF to ON (lamp mode). Heating & A/C System HEATING & A/C SYSTEM System Availability - A Single-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The A/C-Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - Provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The Single-Zone HVAC system uses: One, two-wire electronic blend door actuator. - One, two-wire electronic mode door actuator. - One, two-wire electronic recirculation door actuator. > A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. System Revisions The 2002 AN and AN84 HVAC system remains mostly carryover from 2001. Revisions to the 2002 HVAC system include: New Diagnostic Trouble Codes for a short high on the defog relay control circuit. - A new System Test called the Actuator Circuit Test. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRB III. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRB III. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator (if equipped) from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRB III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1848 - homes and repositions door actuators. - monitors for faults on the actuator circuits. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator (if equipped) to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator (if equipped) from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRB III. - monitors for faults on the actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test: CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause B fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: > indicates that a specific determination of which lines are shorted could not be made. > is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: > XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. > XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. > the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - After the Actuator Circuit Test is run on systems with less than six actuators: > the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). > If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed and the ignition is in the RUN or ACCY position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1849 sends voltage to the cargo lamps. When an unlock button of the RKE is pressed, the cargo lights will turn ON for 30 seconds, similar to the illuminated entry feature. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps and cargo lights due to the following. Leaving a door open, dome lamp switch ON, reading/ vanity lamp switch on or glove box door open for more than 15 minutes while the ignition is OFF. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the LOCK position, all the doors will lock. For unlocking, if the key is turned to the UNLOCK position once, only that door will unlock. If the key is then turned a second time to the UNLOCK position within 4 seconds, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The Highline CTM provides for Remote Keyless Entry (RKE). The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Vehicle Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1850 VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 1851 - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Vehicle Theft Security/System VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. Windshield Wiper System WINDSHIELD WIPER SYSTEM The AN or AN84 truck utilize speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module ( CTM ) High Option: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - chime inoperative Chime Inoperative Exterior/Interior Lamps On & Driver Door Open Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Inoperative With Drivers Seat Belt Unfastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1854 Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire shorted to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1855 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central Timer Module Chime Sounds With Driver Seat Belt Fastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1856 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1857 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense shorted to ground - Central timer module - key-in ignition shorted Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in CTM - Central timer module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1858 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1859 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1860 Down or Page Up function to display the information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1861 Central Timer Module ( CTM ) High Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1862 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8443 Airbag Load Tool 8310 Airbag Load Tool Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Powertrain Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1867 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1868 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1869 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1870 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ............................................................................................................................. 3 - 5 Nm (30 - 40 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1871 Powertrain Control Module: Locations Powertrain Control Module Fig.8 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Powertrain Control Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Powertrain Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2002 Dodge 4.7L JTEC System Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1894 Powertrain Control Module: Description and Operation Fig.8 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/ crank/run position) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1895 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (2.5L engine only) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to- 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1896 - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal. auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1897 Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal.auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1898 PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Ignition Switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5 volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5 volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense circuit and is used to "wake up" the PCM. The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1899 SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1900 Powertrain Control Module: Service and Repair USE THE DRB III SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL Fig.9 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover over the electrical connectors. 3. Carefully unplug the 32-way connectors from PCM. 4. Remove the PCM mounting bolts and remove the PCM from vehicle. INSTALLATION 1. Install the PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the 32-way connectors for corrosion or damage. Repair as necessary 4. Install the 32-way connectors. 5. Install the cover over electrical connectors. 6. Reconnect the negative battery cable. 7. Use the DRB III scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1904 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1905 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1906 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1907 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1908 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1909 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1910 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Oxygen Sensor Downstream Heater Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1914 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1915 Oxygen Sensor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1916 Oxygen Sensor Downstream Heater Relay (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1917 Oxygen Sensor Relay: Description and Operation O2 HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1918 Oxygen Sensor Relay: Service and Repair Fig. 33 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1923 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1924 Fuel Pump Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1925 Fuel Pump Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1926 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1927 Fuel Pump Relay: 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, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1928 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 1929 Fuel Pump Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1933 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1934 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1935 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1936 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1937 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1938 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1939 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1945 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1946 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1947 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1948 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 1952 Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1956 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1957 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1958 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1959 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1960 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1964 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1965 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1966 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1967 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1971 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1972 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1973 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1974 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1975 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 1979 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1983 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1984 Fuel Level Sensor: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector. b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1985 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1986 inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Torque Torque Intake Manifold Air Temp. Sensor 28 Nm 20 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1990 Intake Air Temperature (IAT) Sensor: Locations 4.7L The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1991 Intake Air Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1992 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1993 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Threaded Type Sensor 1. Disconnect electrical connector from sensor. Fig. 37 IAT - 4.7L (Threaded Type) 2. Remove sensor from intake manifold. Snap-In Type Sensor 1. Disconnect electrical connector from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1994 Fig. 39 IAT Sensor Tab/O-Ring - 4.7L (Snap-In Type) Fig. 38 IAT Sensor - 4.7L (Snap-In Type) 3. Gently lift on small plastic release tab and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION Threaded Type Sensor 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Snap-In Type Sensor 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1995 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Torque Torque MAP Sensor Mounting Screws 3 Nm 25 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1999 Manifold Absolute Pressure (MAP) Sensor: Locations 4.7L The MAP sensor is located on the front of the intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2000 Manifold Absolute Pressure Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2001 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When Manifold Absolute Pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops .10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2002 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 43 MAP And ECT Sensor Locations - 4.7L V-8 Engine REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 5. Connect electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2006 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2007 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2008 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque Torque Oxygen Sensor 30 Nm 22 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System 4.7L The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2014 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2015 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2016 Oxygen Sensor 2/2 Downstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2017 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2020 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2021 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. Refer to Wiring Diagrams to determine which relay is used. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on 2.5/3.9/5.2 and 5.9L engines. It is approximately 13.5 ohms on the 4.7L engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2022 package. Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2023 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. Fig. 46 Upstream Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 47 Downstream Oxygen Sensor Location - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2024 Fig. 48 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 49 Left/Right Oxygen Sensor Locations - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2025 Fig. 50 Oxygen Sensor Locations - 4.7L V-8 Engine WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2029 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2030 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2034 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2035 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2036 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2037 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2038 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2039 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2043 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2044 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2049 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2050 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2051 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2052 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2053 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2054 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2055 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2056 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2057 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2058 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2059 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2060 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2061 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2062 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2063 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2064 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2069 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2070 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2071 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2072 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2073 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2074 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2079 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2080 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2081 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2082 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2083 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2087 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2088 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2089 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2090 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2091 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 2096 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 2114 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2115 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2120 right front side of the engine block (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2121 Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service Precautions Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Torque ................................................................................................................................................. ....................................................... 27 Nm (20 ft. lbs) Plug Type ............................................................................................................................................ .............................................................. RC12MCC4 Electrode Gap ...................................................................................................................................... ................................................... 1.01 mm (0.040 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2132 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2133 Spark Plug: Description and Operation All engines use resistor type spark plugs. This engine is equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2134 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig.28 Normal Operation And Cold (Carbon) Fouling Normal Operating The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. On all engines except the 4.7L V-8, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. On the 4.7L V-8, gap growth will not average more than approximately 0.0015 in per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2135 Fig.29 Oil Or Ash Encrusted Oil or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.30 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2136 Fig.31 Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig.32 Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2137 Fig.33 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig.34 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2138 Spark Plug: Service and Repair REMOVAL Fig.35 Heat Shields - 3.9/5.2/5.9L Engines On 3.9L V-6 and 5.2/5.9L V-8 engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 4.7L V-8 Engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. Except 4.7L Engine: Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. 4.7L V-8 Engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 3. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition of coil O-ring and replace as necessary. Fig.37 Cable Removal 4. Except 4.7L: Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 5. Inspect spark plug condition. Refer to Spark Plug Conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2139 CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: The 4.7L V-8 engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. Except 4.7L Engine: When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Except 4.7L Engine: Tighten spark plugs to 35 - 41 Nm (26-30 ft. lbs.) torque. 3. Except 4.7L Engine: Install spark plug cables over spark plugs. 4. 4.7L V-8 Engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 5. 4.7L V-8 Engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 6. 4.7L V-8 Engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2143 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Torque Torque Intake Manifold Air Temp. Sensor 28 Nm 20 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2151 Intake Air Temperature (IAT) Sensor: Locations 4.7L The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2152 Intake Air Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2153 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2154 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Threaded Type Sensor 1. Disconnect electrical connector from sensor. Fig. 37 IAT - 4.7L (Threaded Type) 2. Remove sensor from intake manifold. Snap-In Type Sensor 1. Disconnect electrical connector from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2155 Fig. 39 IAT Sensor Tab/O-Ring - 4.7L (Snap-In Type) Fig. 38 IAT Sensor - 4.7L (Snap-In Type) 3. Gently lift on small plastic release tab and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION Threaded Type Sensor 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Snap-In Type Sensor 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2156 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2160 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2161 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2162 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2163 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations Central Timer Module ( CTM ) High Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2167 Central Timer Module ( CTM ) High Option: Diagrams Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2168 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2169 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information DANGER!!! ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection and remove any metal jewelry, such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2172 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "lock" position. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the Miller tool #8815 (not the wire end or terminal) in the connector. Do not probe a wire through the insulation; this will damage the wire and eventually cause the wire to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description Central Timer Module ( CTM ) High Option: Description and Operation System Description SYSTEM DESCRIPTION The body system on the Dakota (AN) and Dakota Quad Cab (AN84) consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2175 Central Timer Module ( CTM ) High Option: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/ Mechanical Instrument Cluster (EMIC and CTM) from the ACM via the PCI bus. The AIRBAG warning lamp and chime are the only point at which "symptoms" of a system malfunction can be observed by the customer. When- ever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF; there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Passenger Side Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. 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. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. SPECIAL TOOLS Some airbag diagnostic test use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver and Passenger Airbag, clockspring, or seat belt tensioner (use a jumper if needed). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2176 Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective components has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed squib wiring can be tested for open and shorted conditions. SEAT BELT TENSIONER Front seat belt systems incorporate Seat Belt Tensioner (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2177 remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Central Timer Module CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) - Horn Chirp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2178 - Optical Chirp The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. Chime System CHIME SYSTEM The chime system is built into the CTM. There are two chime rates - Low: 50 chimes per minute for reminders, and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left ON. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light ON the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Ignition OFF, cargo lights ON, drivers door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning (if vehicle speed>0) - Transmission temperature lamp - Turn signal ON reminder warning - Button pushed on compass mini-trip computer (reset) - ABS light ON - Over speed warning GULF COAST COUNTRY (GCC only) - Water in fuel (diesel) Compass/Mini-Trip Computer (CMTC) COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (Miles Per Gallon) or 1/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or 1/100 Km. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions and a chime will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2179 the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly OFF of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Head-lamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. Enhanced Accident Response ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Exterior Lighting EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition Off while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF, The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON, the delay will be canceled and the headlamps will turn OFF immediately. During the delay period, only the headlamps are turned ON and the park lamps/fog lamps are turned OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2180 The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned OFF and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. A 15 minute timeout is initiated if the ignition is OFF and the headlamp switch is cycled from OFF to ON (lamp mode). Heating & A/C System HEATING & A/C SYSTEM System Availability - A Single-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The A/C-Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - Provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The Single-Zone HVAC system uses: One, two-wire electronic blend door actuator. - One, two-wire electronic mode door actuator. - One, two-wire electronic recirculation door actuator. > A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. System Revisions The 2002 AN and AN84 HVAC system remains mostly carryover from 2001. Revisions to the 2002 HVAC system include: New Diagnostic Trouble Codes for a short high on the defog relay control circuit. - A new System Test called the Actuator Circuit Test. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRB III. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRB III. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator (if equipped) from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRB III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2181 - homes and repositions door actuators. - monitors for faults on the actuator circuits. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator (if equipped) to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator (if equipped) from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRB III. - monitors for faults on the actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test: CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause B fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: > indicates that a specific determination of which lines are shorted could not be made. > is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: > XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. > XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. > the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - After the Actuator Circuit Test is run on systems with less than six actuators: > the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). > If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed and the ignition is in the RUN or ACCY position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2182 sends voltage to the cargo lamps. When an unlock button of the RKE is pressed, the cargo lights will turn ON for 30 seconds, similar to the illuminated entry feature. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps and cargo lights due to the following. Leaving a door open, dome lamp switch ON, reading/ vanity lamp switch on or glove box door open for more than 15 minutes while the ignition is OFF. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the LOCK position, all the doors will lock. For unlocking, if the key is turned to the UNLOCK position once, only that door will unlock. If the key is then turned a second time to the UNLOCK position within 4 seconds, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The Highline CTM provides for Remote Keyless Entry (RKE). The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Vehicle Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2183 VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2184 - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Vehicle Theft Security/System VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. Windshield Wiper System WINDSHIELD WIPER SYSTEM The AN or AN84 truck utilize speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module ( CTM ) High Option: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - chime inoperative Chime Inoperative Exterior/Interior Lamps On & Driver Door Open Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Inoperative With Drivers Seat Belt Unfastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2187 Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire shorted to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2188 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central Timer Module Chime Sounds With Driver Seat Belt Fastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2189 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2190 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense shorted to ground - Central timer module - key-in ignition shorted Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in CTM - Central timer module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2191 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2192 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2193 Down or Page Up function to display the information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2194 Central Timer Module ( CTM ) High Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2195 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8443 Airbag Load Tool 8310 Airbag Load Tool Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations > Page 2200 Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2204 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2205 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2206 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2207 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2208 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2212 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2213 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2214 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2215 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2219 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2220 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2221 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2222 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2223 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations The data link connector is located at the lower edge of the instrument panel near the steering column. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Data Link Connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2246 Data Link Connector: Description and Operation The data link connector is located at the lower edge of the instrument panel near the steering column. The 16-way data link connector (diagnostic scan tool connector) links the Diagnostic Readout Box (DRB III) scan tool or the Mopar Diagnostic System (MDS) with the Powertrain Control Module (PCM). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 2251 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Powertrain Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2256 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2257 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2258 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2259 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ............................................................................................................................. 3 - 5 Nm (30 - 40 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2260 Powertrain Control Module: Locations Powertrain Control Module Fig.8 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Powertrain Control Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 Powertrain Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2002 Dodge 4.7L JTEC System Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2283 Powertrain Control Module: Description and Operation Fig.8 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/ crank/run position) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2284 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (2.5L engine only) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to- 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2285 - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal. auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2286 Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal.auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2287 PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Ignition Switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5 volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5 volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense circuit and is used to "wake up" the PCM. The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2288 SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2289 Powertrain Control Module: Service and Repair USE THE DRB III SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL Fig.9 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover over the electrical connectors. 3. Carefully unplug the 32-way connectors from PCM. 4. Remove the PCM mounting bolts and remove the PCM from vehicle. INSTALLATION 1. Install the PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the 32-way connectors for corrosion or damage. Repair as necessary 4. Install the 32-way connectors. 5. Install the cover over electrical connectors. 6. Reconnect the negative battery cable. 7. Use the DRB III scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 2293 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2297 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2298 Fuel Level Sensor: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector. b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2299 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2300 inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications Torque Torque IAC Motor-To-Throttle Body Bolts 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2304 Idle Air Control (IAC) Motor: Locations The IAC motor is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2305 Idle Air Control Motor (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2306 Idle Air Control (IAC) Motor: Description and Operation The IAC stepper motor is mounted to the throttle body and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: - Off-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC step-per motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the IAC motor through the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2307 Idle Air Control (IAC) Motor: Service and Repair REMOVAL The IAC motor is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect electrical connector from IAC motor. Fig. 62 TPS Mounting Bolts - 3.9/5.2/5.9L Engines 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 Information Bus: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 Diagnostic Junction Port Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 Information Bus: Electrical Diagrams Body Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 PCM Communication Wiring Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 8w-18-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 8w-18-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Programmable Communication Interface (PCI) Bus Information Bus: Description and Operation Programmable Communication Interface (PCI) Bus The Programmable Communication Interface (PCI) data bus system is a single wire multiplex system used for vehicle communications. Multiplexing is a system that enables the transmission of several messages over a single channel or circuit. Many of the control modules in a vehicle require information from the same sensing device. Multiplexing reduces wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to only one controller, which reads and distributes the sensor information to the other controllers over the data bus. Also, because each controller on the data bus can access the controller sensor inputs to every other controller on the data bus, more function and feature capabilities are possible. A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool. This system allows a control module to broadcast message data out onto the bus where all other control modules can read the messages that are being sent. When a module reads a message on the data bus that it requires, it relays that message to its microprocessor. Each module ignores the messages on the data bus that it dosen't recognize. Data exchange between modules is achieved by serial transmission of encoded data over a single wire broadcast network. The PCI data bus messages are carried over the bus in the form of Variable Pulse Width Modulated (VPWM) signals. The PCI data bus speed is an average 10.4 Kilo-bits per second (Kbps). The voltage network used to transmit messages requires biasing and termination. Each module on the PCI data bus system provides its own biasing and termination. Each module (also referred to as a node) terminates the bus through a terminating resistor and a terminating capacitor. The Powertrain Control Module (PCM) is the only dominant node for the PCI data bus system. The PCI bus uses low and high voltage levels to generate signals. The voltage on the bus varies between 0 and 7-1/2 volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. When a module is transmitting on the bus it is reading the bus at the same time to ensure message integrity Each module is capable of transmitting and receiving data simultaneously The PCI data bus can be monitored using the DRB III scan tool It is possible for the bus to pass all DRB III tests and still be faulty if the voltage parameters are all within the specified range and false messages are being sent Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Programmable Communication Interface (PCI) Bus > Page 2335 Information Bus: Description and Operation Vehicle Communication Overview VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Programmable Communication Interface (PCI) Bus > Page 2336 - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 Volt square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2340 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2341 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2342 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2343 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2344 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2345 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2346 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 2350 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ................................................................... LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 2351 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a 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 icon to appear in amber through the translucent outer layer of the overlay when the indicator 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. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) 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 seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-OFF message automatically Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters. - Communication Error - If the cluster receives no lamp-ON message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-on message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-OFF messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Torque Torque MAP Sensor Mounting Screws 3 Nm 25 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2355 Manifold Absolute Pressure (MAP) Sensor: Locations 4.7L The MAP sensor is located on the front of the intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2356 Manifold Absolute Pressure Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2357 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When Manifold Absolute Pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops .10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2358 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 43 MAP And ECT Sensor Locations - 4.7L V-8 Engine REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 5. Connect electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2362 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2363 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2364 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque Torque Oxygen Sensor 30 Nm 22 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System 4.7L The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2370 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2371 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2372 Oxygen Sensor 2/2 Downstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2373 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2376 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2377 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. Refer to Wiring Diagrams to determine which relay is used. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on 2.5/3.9/5.2 and 5.9L engines. It is approximately 13.5 ohms on the 4.7L engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2378 package. Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2379 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. Fig. 46 Upstream Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 47 Downstream Oxygen Sensor Location - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2380 Fig. 48 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 49 Left/Right Oxygen Sensor Locations - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2381 Fig. 50 Oxygen Sensor Locations - 4.7L V-8 Engine WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Oxygen Sensor Downstream Heater Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2385 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2386 Oxygen Sensor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2387 Oxygen Sensor Downstream Heater Relay (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2388 Oxygen Sensor Relay: Description and Operation O2 HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2389 Oxygen Sensor Relay: Service and Repair Fig. 33 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2393 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2394 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations Central Timer Module ( CTM ) High Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2399 Central Timer Module ( CTM ) High Option: Diagrams Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2400 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 2401 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information DANGER!!! ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection and remove any metal jewelry, such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2404 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "lock" position. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the Miller tool #8815 (not the wire end or terminal) in the connector. Do not probe a wire through the insulation; this will damage the wire and eventually cause the wire to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description Central Timer Module ( CTM ) High Option: Description and Operation System Description SYSTEM DESCRIPTION The body system on the Dakota (AN) and Dakota Quad Cab (AN84) consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2407 Central Timer Module ( CTM ) High Option: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/ Mechanical Instrument Cluster (EMIC and CTM) from the ACM via the PCI bus. The AIRBAG warning lamp and chime are the only point at which "symptoms" of a system malfunction can be observed by the customer. When- ever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF; there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Passenger Side Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. 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. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. SPECIAL TOOLS Some airbag diagnostic test use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver and Passenger Airbag, clockspring, or seat belt tensioner (use a jumper if needed). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2408 Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective components has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed squib wiring can be tested for open and shorted conditions. SEAT BELT TENSIONER Front seat belt systems incorporate Seat Belt Tensioner (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2409 remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Central Timer Module CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) - Horn Chirp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2410 - Optical Chirp The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. Chime System CHIME SYSTEM The chime system is built into the CTM. There are two chime rates - Low: 50 chimes per minute for reminders, and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left ON. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light ON the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Ignition OFF, cargo lights ON, drivers door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning (if vehicle speed>0) - Transmission temperature lamp - Turn signal ON reminder warning - Button pushed on compass mini-trip computer (reset) - ABS light ON - Over speed warning GULF COAST COUNTRY (GCC only) - Water in fuel (diesel) Compass/Mini-Trip Computer (CMTC) COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (Miles Per Gallon) or 1/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or 1/100 Km. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions and a chime will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2411 the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly OFF of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Head-lamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. Enhanced Accident Response ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Exterior Lighting EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition Off while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF, The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON, the delay will be canceled and the headlamps will turn OFF immediately. During the delay period, only the headlamps are turned ON and the park lamps/fog lamps are turned OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2412 The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned OFF and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. A 15 minute timeout is initiated if the ignition is OFF and the headlamp switch is cycled from OFF to ON (lamp mode). Heating & A/C System HEATING & A/C SYSTEM System Availability - A Single-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The A/C-Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - Provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The Single-Zone HVAC system uses: One, two-wire electronic blend door actuator. - One, two-wire electronic mode door actuator. - One, two-wire electronic recirculation door actuator. > A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. System Revisions The 2002 AN and AN84 HVAC system remains mostly carryover from 2001. Revisions to the 2002 HVAC system include: New Diagnostic Trouble Codes for a short high on the defog relay control circuit. - A new System Test called the Actuator Circuit Test. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRB III. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRB III. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator (if equipped) from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRB III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2413 - homes and repositions door actuators. - monitors for faults on the actuator circuits. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator (if equipped) to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator (if equipped) from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRB III. - monitors for faults on the actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test: CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause B fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: > indicates that a specific determination of which lines are shorted could not be made. > is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: > XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. > XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. > the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - After the Actuator Circuit Test is run on systems with less than six actuators: > the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). > If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed and the ignition is in the RUN or ACCY position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2414 sends voltage to the cargo lamps. When an unlock button of the RKE is pressed, the cargo lights will turn ON for 30 seconds, similar to the illuminated entry feature. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps and cargo lights due to the following. Leaving a door open, dome lamp switch ON, reading/ vanity lamp switch on or glove box door open for more than 15 minutes while the ignition is OFF. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the LOCK position, all the doors will lock. For unlocking, if the key is turned to the UNLOCK position once, only that door will unlock. If the key is then turned a second time to the UNLOCK position within 4 seconds, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The Highline CTM provides for Remote Keyless Entry (RKE). The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Vehicle Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2415 VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 2416 - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Vehicle Theft Security/System VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. Windshield Wiper System WINDSHIELD WIPER SYSTEM The AN or AN84 truck utilize speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module ( CTM ) High Option: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - chime inoperative Chime Inoperative Exterior/Interior Lamps On & Driver Door Open Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Inoperative With Drivers Seat Belt Unfastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2419 Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire shorted to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2420 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central Timer Module Chime Sounds With Driver Seat Belt Fastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2421 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2422 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense shorted to ground - Central timer module - key-in ignition shorted Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in CTM - Central timer module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2423 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2424 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2425 Down or Page Up function to display the information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2426 Central Timer Module ( CTM ) High Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2427 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8443 Airbag Load Tool 8310 Airbag Load Tool Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Powertrain Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2432 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2433 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2434 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2435 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ............................................................................................................................. 3 - 5 Nm (30 - 40 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2436 Powertrain Control Module: Locations Powertrain Control Module Fig.8 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2452 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2453 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2454 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2455 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2456 Powertrain Control Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2457 Powertrain Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2458 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2002 Dodge 4.7L JTEC System Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2459 Powertrain Control Module: Description and Operation Fig.8 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/ crank/run position) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2460 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (2.5L engine only) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to- 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2461 - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal. auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2462 Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal.auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2463 PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Ignition Switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5 volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5 volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense circuit and is used to "wake up" the PCM. The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2464 SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2465 Powertrain Control Module: Service and Repair USE THE DRB III SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL Fig.9 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover over the electrical connectors. 3. Carefully unplug the 32-way connectors from PCM. 4. Remove the PCM mounting bolts and remove the PCM from vehicle. INSTALLATION 1. Install the PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the 32-way connectors for corrosion or damage. Repair as necessary 4. Install the 32-way connectors. 5. Install the cover over electrical connectors. 6. Reconnect the negative battery cable. 7. Use the DRB III scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2469 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2470 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2471 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2472 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2473 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2474 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2475 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Oxygen Sensor Downstream Heater Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2479 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2480 Oxygen Sensor Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2481 Oxygen Sensor Downstream Heater Relay (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2482 Oxygen Sensor Relay: Description and Operation O2 HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2483 Oxygen Sensor Relay: Service and Repair Fig. 33 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2488 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2489 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2490 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2491 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 2495 Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2499 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2500 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2501 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2502 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2503 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Torque Torque Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2507 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2508 Engine Coolant Temperature Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2509 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: For engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (AC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2510 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2514 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2515 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2516 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2517 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2518 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 2522 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2526 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2527 Fuel Level Sensor: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector. b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2528 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module or. The fuel pump module is located Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2529 inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Torque Torque Intake Manifold Air Temp. Sensor 28 Nm 20 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2533 Intake Air Temperature (IAT) Sensor: Locations 4.7L The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2534 Intake Air Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2535 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2536 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Threaded Type Sensor 1. Disconnect electrical connector from sensor. Fig. 37 IAT - 4.7L (Threaded Type) 2. Remove sensor from intake manifold. Snap-In Type Sensor 1. Disconnect electrical connector from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2537 Fig. 39 IAT Sensor Tab/O-Ring - 4.7L (Snap-In Type) Fig. 38 IAT Sensor - 4.7L (Snap-In Type) 3. Gently lift on small plastic release tab and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION Threaded Type Sensor 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Snap-In Type Sensor 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2538 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications Torque Torque MAP Sensor Mounting Screws 3 Nm 25 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2542 Manifold Absolute Pressure (MAP) Sensor: Locations 4.7L The MAP sensor is located on the front of the intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2543 Manifold Absolute Pressure Sensor (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2544 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When Manifold Absolute Pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops .10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2545 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 43 MAP And ECT Sensor Locations - 4.7L V-8 Engine REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 5. Connect electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2549 Engine Oil Pressure Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2550 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2551 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Torque Torque Oxygen Sensor 30 Nm 22 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System 4.7L The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2557 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2558 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2559 Oxygen Sensor 2/2 Downstream (California) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2560 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2563 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2564 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. Refer to Wiring Diagrams to determine which relay is used. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on 2.5/3.9/5.2 and 5.9L engines. It is approximately 13.5 ohms on the 4.7L engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2565 package. Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2566 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. Fig. 46 Upstream Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 47 Downstream Oxygen Sensor Location - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2567 Fig. 48 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations - Except 4.7L V-8 Engine Fig. 49 Left/Right Oxygen Sensor Locations - Except 4.7L V-8 Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2568 Fig. 50 Oxygen Sensor Locations - 4.7L V-8 Engine WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2572 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2573 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2577 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2578 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2579 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2580 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2581 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2582 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2586 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2587 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2592 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2593 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2594 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2595 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2596 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2597 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2598 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2599 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2600 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2601 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2602 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2603 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2604 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2605 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2606 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2607 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2611 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2612 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2613 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2614 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2615 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2616 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2620 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2621 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2647 Proportional Purge Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2648 Canister Purge Solenoid: Description and Operation The duty cycle EVAP canister purge solenoid (DCP) regulates the rate of vapor flow from the EVAP canister to the intake manifold. The Powertrain Control Module (PCM) operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM cycles (energizes and de-energizes) the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time that the solenoid is energized. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Torque Torque EVAP Canister Mounting Nut 17-24 Nm 50-210 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2652 Evaporative Emission Control Canister: Locations Fig. 23 EVAP Canister Location The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2653 Evaporative Emission Control Canister: Description and Operation Fig. 23 EVAP Canister Location VAPOR CANISTER A maintenance free, EVAP canister is used on all vehicles. The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2654 Evaporative Emission Control Canister: Service and Repair Fig. 24 EVAP Canister Location REMOVAL The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. 1. Raise vehicle. 2. Disconnect vacuum lines at EVAP canister. Note location of lines before removal. 3. Remove canister mounting nut. 4. Remove canister from mounting bracket. INSTALLATION The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. 1. Position canister locating pins into mounting bracket grommets and install mounting nut. 2. Tighten mounting nut to 17-24 Nm (150-210 in. lbs.) torque. 3. Connect vacuum lines at canister. 4. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications Leak Detection Pump: Specifications Torque Torque Leak Detection Pump (LDP) Mounting Screws 1 Nm 11 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2658 Leak Detection Pump: Locations Fig. 4 Leak Detection Pump (LDP) Location Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2659 Fig. 5 LDP Filter Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2660 Leak Detection Pump Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2661 Leak Detection Pump: Description and Operation The Leak Detection Pump (LDP) is used only with certain emission packages. The LDP is a device used to detect a leak in the evaporative system. The pump contains a 3 port solenoid, a pump that contains a switch, a spring loaded canister vent valve seal, 2 check valves and a spring/diaphragm. Immediately after a cold start, engine temperature between 40 °F and 86 °F, the 3 port solenoid is briefly energized. This initializes the pump by drawing air into the pump cavity and also closes the vent seal. During non-test test conditions, the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel position. The vent seal will remain closed while the pump is cycling. This is due to the operation of the 3 port solenoid which prevents the diaphragm assembly from reaching full travel. After the brief initialization period, the solenoid is de-energized, allowing atmospheric pressure to enter the pump cavity. This permits the spring to drive the diaphragm which forces air out of the pump cavity and into the vent system. When the solenoid is energized and de-energized, the cycle is repeated creating flow in typical diaphragm pump fashion. The pump is controlled in 2 modes: Pump Mode: The pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test time. Test Mode: The solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the diaphragm reaches the switch closure point. The spring in the pump is set so that the system will achieve an equalized pressure of about 7.5 inches of water. When the pump starts, the cycle rate is quite high. As the system becomes pressurized pump rate drops. If there is no leak the pump will quit. If there is a leak, the test is terminated at the end of the test mode. If there is no leak, the purge monitor is run. If the cycle rate increases due to the flow through the purge system, the test is passed and the diagnostic is complete. The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2662 Leak Detection Pump: Testing and Inspection LEAK DETECTION PUMP Leak Detection Pump Operation The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system test for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. EVAP Leak Detection System Components Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister: The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5" HO (1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2663 The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns ON and OFF. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid ON and OFF. LDP At Rest (Not Powered) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2664 Diaphragm Upward Movement When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Diaphragm Downward Movement Based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PCM to monitor LDP pumping (diaphragm up/down) activity, During the pumping mode, the diaphragm will not move down far enough to open the vent valve. The pumping cycle is repeated as the solenoid is turned ON and OFF. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. Pumping Action During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid ON and OFF to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2665 - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT Enabling Conditions To Run EVAP Leak Detection Test 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4 °C (40 °F) and 32 °C (90 °F) for 0.040 leak. Between 4 °C (40 °F) and 29 °C (85 °F) for 0.020 leak. 2. Engine coolant temperature within: -12 ° to -8 °C (10 ° to 18 °F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP Leak Detection Test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85%). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test monitor test screen on the DRB III. See TSB 25-002-98 for more detail. A DTC will not set if a one-trip fault is set or if the MIL is illuminated for any of the following: Purge Solenoid - All engine Controller Self Test Faults - All Cam and/or Crank Sensor Faults - MAP Sensor Faults - Ambient/Battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Faults - EGR Solenoid Electrical Faults - All Injector Faults - Baro Out Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Figure 6 Section 1 When the ignition key is turned to "ON", the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is cancelled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P04441. These temperature calibrations may be different between models. Figure 6 Section 2 If DTCP1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2666 energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P 1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. Figure 5 Section 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns off the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. Figure 6 Section 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. Figure 6 Section 5 Next, the PCM performs one or more tests cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned OFF. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or larger leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. Diagnostic Tips During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections, Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can be set due to pressure being in the EVAP system during the test sequence. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2667 Multiple actuation's of the DRB III Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing for high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. Test Equipment The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an IW trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. Important Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB III Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2668 Leak Detection Pump: Service and Repair REMOVAL Fig. 4 Leak Detection Pump (LDP) Location Fig. 5 LDP Filter Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. 1. Disconnect negative battery cable at battery. 2. Remove battery Refer to Battery for procedures. 3. Carefully disconnect rubber hose from bottom of LDP filter. 4. Remove clip retaining LDP filter to battery tray and remove filter from tray. 5. Disconnect battery temperature sensor pigtail wiring harness at bottom of battery tray. 6. To gain access to LDP; the PDC must be partially removed. Remove PDC-to-fender mounting screw at rear of PDC. Unsnap PDC from battery tray To prevent damage to PDC wiring, carefully position PDC to gain access to LDP. 7. Remove battery tray. Refer to Battery for procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2669 8. Carefully remove vapor/vacuum lines at LDR. 9. Disconnect electrical connector at LDP. Fig. 6 Leak Detection Pump (LDP) Mounting Screws 10. Remove 3 LDP mounting screws and remove LDP from vehicle. INSTALLATION The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. 1. Install LDP to bottom of battery tray. Tighten screws to 1 Nm (11 in. lbs.) torque. 2. Carefully install vapor/vacuum lines to LDR The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 3. Connect electrical connector to LDP. 4. Install battery tray. Refer to Battery for procedures. 5. Install PDC to fender and battery tray (snaps on to battery tray). 6. Install LDP filter to battery tray (one clip). 7. Install connecting hose to bottom of LDP filter. 8. Connect battery temperature sensor pigtail wiring harness. 9. Install battery Refer to Battery for procedures. 10. Connect negative battery cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Line > Component Information > Description and Operation EGR Vacuum Line: Description and Operation A vacuum schematic for emission related items can be found on the VECI label Refer to Vehicle Emission Control Information (VECI) Label for label location. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations The PCV valve (6) is located on the oil filler tube (4). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 2687 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 2688 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Torque Torque Accelerator Pedal Bracket Mounting Nuts 7 Nm 65 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2695 Accelerator Pedal: Service Precautions CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Minimum Octane Rating ...................................................................................................................... .................................................................. 87 octane Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Page 2703 Fuel: Service Precautions CAUTION: Do not use gasoline containing Methanol. Gasoline containing methanol may damage critical fuel system components. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-02A > Oct > 02 > Fuel System Difficult Fuel Filler Cap Removal Fuel Filler Cap: Customer Interest Fuel System - Difficult Fuel Filler Cap Removal NUMBER: 14-001-02 REV A GROUP: Fuel DATE: Oct. 7, 2002 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS FOR LH-VEHICLES OR PERFORM ANY ACTIONS RELATED TO LH-VEHICLES LISTED IN THIS BULLETIN UNTIL OCTOBER 7, 2002. PARTS ARE IMMEDIATELY AVAILABLE FOR ALL OTHER INVOLVED VEHICLES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-02, DATED MAY 6, 2002. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fuel Cap Difficult To Remove OVERVIEW: This bulletin involves installing a revised fuel cap. MODELS AFFECTED SYMPTOM/CONDITION: Fuel cap is difficult to remove after being tightened and not removed for one day or more. If the cap is removed immediately after tightening the condition may not be apparent. DIAGNOSIS: If the vehicle operator describes the condition perform the Repair Procedure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-02A > Oct > 02 > Fuel System Difficult Fuel Filler Cap Removal > Page 2712 PARTS REQUIRED REPAIR PROCEDURE: 1. Remove the fuel cap from the filler neck. 2. Remove the fuel cap tether attachment from the body. 3. Discard the old cap assembly. 4. Clean off any residue on the filler neck and the threaded area of the fuel cap. 5. Install the tether of the new fuel cap assembly to the body. 6. Install the fuel cap. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-02A > Oct > 02 > Fuel System - Difficult Fuel Filler Cap Removal Fuel Filler Cap: All Technical Service Bulletins Fuel System - Difficult Fuel Filler Cap Removal NUMBER: 14-001-02 REV A GROUP: Fuel DATE: Oct. 7, 2002 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS FOR LH-VEHICLES OR PERFORM ANY ACTIONS RELATED TO LH-VEHICLES LISTED IN THIS BULLETIN UNTIL OCTOBER 7, 2002. PARTS ARE IMMEDIATELY AVAILABLE FOR ALL OTHER INVOLVED VEHICLES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-02, DATED MAY 6, 2002. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fuel Cap Difficult To Remove OVERVIEW: This bulletin involves installing a revised fuel cap. MODELS AFFECTED SYMPTOM/CONDITION: Fuel cap is difficult to remove after being tightened and not removed for one day or more. If the cap is removed immediately after tightening the condition may not be apparent. DIAGNOSIS: If the vehicle operator describes the condition perform the Repair Procedure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-02A > Oct > 02 > Fuel System - Difficult Fuel Filler Cap Removal > Page 2718 PARTS REQUIRED REPAIR PROCEDURE: 1. Remove the fuel cap from the filler neck. 2. Remove the fuel cap tether attachment from the body. 3. Discard the old cap assembly. 4. Clean off any residue on the filler neck and the threaded area of the fuel cap. 5. Install the tether of the new fuel cap assembly to the body. 6. Install the fuel cap. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 2719 Fuel Filler Cap: Description and Operation The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube Certain models are equipped with a 1/4 turn cap The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with a California emissions package and a Leak Detection Pump (LDP), the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 2720 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 2726 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2727 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications Fuel Hose Clamp: Specifications Torque Torque Fuel Hose Clamps 3 Nm 25 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 2731 Fuel Hose Clamp: Description and Operation FUEL LINES Also refer to Quick-Connect Fittings. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Resistance 12.0 ohms +/- 1.2 ohms At 20 degrees C (68 degrees F) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2735 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2736 Fuel Injector: Diagrams Fuel Injector No.1 Fuel Injector No.2 Fuel Injector No.3 Fuel Injector No.4 Fuel Injector No.5 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2737 Fuel Injector No.6 Fuel Injector No.7 Fuel Injector No.8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2738 Fuel Injector: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2739 Fuel Injector: Description and Operation Fig. 32 Fuel Injector - Typical An individual fuel injector (Fig 32) is used for each individual cylinder The top (fuel entry) end of the injector (Fig. 32) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector ON and OFF. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. PCM Output The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector ON and OFF. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shutdown the 12 volt power source to the fuel injectors if the PCM senses the ignition is ON, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds. The PCM determines injector on-time (pulse width) based on various inputs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2740 Fuel Injector: Testing and Inspection To perform a complete test of the fuel injectors and their circuitry use the DRB scan tool and refer to the appropriate Powertrain Diagnostics Procedures manual. To test the injector only, refer to the following: Disconnect the fuel injector wire harness connector from the injector. The injector is equipped with 2 electrical terminals (pins). Place an ohmmeter across the terminals. Resistance reading should be approximately 12 ohms ± 1.2 ohms at 20 °C (68 °F). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2741 Fuel Injector: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. To remove one or more fuel injectors, fuel rail assembly must be removed from engine. 1. Remove air cleaner assembly. 2. Remove fuel injector rail assembly Refer to Fuel Injector Rail Removal/Installation in this group. Fig. 24 CKP Sensor Location - 4.7L V-8 Engine 3. Remove clip(s) retaining the injector(s) to fuel rail (Fig. 24). 4. Remove injector(s) from fuel rail. INSTALLATION WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. To remove one or more fuel injectors, fuel rail assembly must be removed from engine. 1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly. Refer to Fuel Injector Rail Removal/Installation. 4. Install air cleaner. 5. Start engine and check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2745 Fuel Line Coupler: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2746 Fuel Line Coupler: Description and Operation QUICK CONNECT FITTING Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2747 Fuel Line Coupler: Service and Repair STANDARD PROCEDURE - QUICK-CONNECT FITTINGS Also refer to Fuel Tubes/Lines/Hoses and Clamps. Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Safety latch clips are used on certain components/lines. Certain fittings may require use of a special tool for disconnection. Disconnecting WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: The interior components (O-rings, spacers) of some types of quick-connect fitting are not serviced separately. If service parts are not available, do not attempt to repair a damaged fitting or fuel line. If repair is necessary, replace complete fuel line assembly. 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. Fig. 35 2-Button Type Fitting 4. 2-Button Type Fitting: This type of fitting is equipped with a push-button located on each side of quick-connect fitting (Fig. 35). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2748 Fig. 36 Pinch Type Quick-Connect Fitting 5. Pinch-Type Fitting: This fitting is equipped with two finger tabs. Pinch both tabs together while removing fitting (Fig. 36). Special tools are not required for disconnection. Fig. 37 Single-Tab Type Fitting 6. Single-Tab Type Fitting: This type of fitting is equipped with a single pull tab (Fig. 37). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. a. Press release tab on side of fitting to release pull tab (Fig. 38). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2749 Fig. 38 Disconnecting Single-Tab Type Fitting b. While pressing release tab on side of fitting, use screwdriver to pry up pull tab (Fig. 38). Fig. 39 Removing Pull Tab c. Raise pull tab until it separates from quick-connect fitting (Fig. 39). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2750 Fig. 40 Typical 2-Tab Type Fitting 7. Two-Tab Type Fitting: This type of fitting is equipped with tabs located on both sides of fitting (Fig. 40). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 40) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Fig. 41 Plastic Retainer Ring Type Fitting 8. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 41) usually black in color. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2751 a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 41). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body c. Inspect fitting connector body plastic retainer ring and fuel system component for damage. Replace as necessary. Fig. 42 Latch Clip-Type 1 Fig. 43 Latch Clip-Type 2 9. Latch Clips: Depending on vehicle model and engine, 2 different types of safety latch clips are used (Fig. 42) or (Fig. 43). Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. a. Type 1: Pry up on latch clip with a screwdriver (Fig. 42). b. Type 2: Separate and unlatch 2 small arms on end of clip (Fig. 43) and swing away from fuel line. c. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2752 Fig. 44 Fuel Line Disconnection Using Special Tool d. Insert special fuel line removal tool (Snap-On number FIFI 9055-1 or equivalent) into fuel line (Fig. 44). Use tool to release locking fingers in end of line. e. With special tool still inserted, pull fuel line from fuel rail. f. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 10. Disconnect quick-connect fitting from fuel system component being serviced. Connecting 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations A combination fuel filter and fuel pressure regulator is used on all engines. It is located on the top of the fuel pump module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2756 Fuel Pressure Regulator: Description and Operation Fig. 2 Side View - Filter/Regulator FUEL FILTER/PRESSURE REGULATOR A combination fuel filter and fuel pressure regulator (Fig. 2) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the powertrain control module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 2) is also part of the assembly Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator (Fig. 2). The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump-Description and Operation for more information. Also refer to the Fuel Pressure Leak Down Test and the Fuel Pump Pressure Tests. If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service They do not require normal scheduled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2768 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2769 Fuel Pump Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2770 Fuel Pump Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2771 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2772 Fuel Pump Relay: 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, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2773 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2774 Fuel Pump Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 2778 Fuel Pump Pickup Filter: Service and Repair Fig. 33 Fuel Pump Inlet Filter - 2 Door Models Fig. 34 Fuel Pump Inlet Filter - 4 Door Models REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 33) or (Fig. 34). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. 4 Door Models: Remove filter by carefully prying it from bottom of pump module with 2 screwdrivers. Filter is snapped to module. 5. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 33) or (Fig. 34). The fuel pump module is located inside of Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 2779 fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Torque Torque Fuel Rail Mounting Bolts 27 Nm 20 Ft. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2783 Fuel Rail: Locations 4.7L A fuel pressure test port is located on the fuel rail. A quick-connect fitting with a safety latch is used to attach the fuel line to the fuel rail. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2784 Fuel Rail: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2785 Fuel Rail: Description and Operation Fig. 18 Fuel Injector Rail - 4.7L V-8 Engine The fuel injector rail is used to mount the fuel injectors to the engine. It is mounted to the intake manifold (Fig. 18). High pressure fuel from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A fuel pressure test port is located on the fuel rail (Fig. 18). A quick-connect fitting with a safety latch is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2786 Fuel Rail: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL , FUEL SYSTEM PRESSURE MUST BE RELEASED. Fig. 26 Fuel Rail Mounting - 4.7L V-8 Engine CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (Fig. 26). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube. 1. Remove fuel tank filler tube cap. 2. Perform Fuel System Pressure Release Procedure. 3. Remove negative battery cable at battery. 4. Remove air duct at throttle body air box. 5. Remove air box at throttle body 6. Remove wiring at rear of generator. 7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings. 8. Remove vacuum lines at throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2787 Fig. 27 Remove/Install Injector Connector - 4.7L V-8 Engine 9. Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 27). Push red colored slider away from injector (1). While pushing slider depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal. 10. Disconnect electrical connectors at throttle body 11. Disconnect electrical connectors at MAP and IAT sensors. 12. Remove first three ignition coils on each bank (cylinders # 1, 3, 5, 2, 4 and 6). Refer to Ignition Coil Removal/Installation. 13. Remove 4 fuel rail mounting bolts (Fig. 26). 14. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes. 15. Remove fuel rail (with injectors attached) from engine. 16. If fuel injectors are to be removed, refer to Fuel Injector Removal/Installation. INSTALLATION 1. If fuel injectors are to be installed, refer to Fuel Injector Removal/Installation. 2. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. 3. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head. 4. Guide each injector into cylinder head. Be careful not to tear injector O-rings. 5. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder. 6. Install 4 fuel rail mounting bolts and tighten to 27 Nm (20 ft. lbs.). 7. Install ignition coils. Refer to Ignition Coil Removal/Installation. 8. Connect electrical connectors to throttle body. 9. Connect electrical connectors to MAP and IAT sensors. 10. Connect electrical connectors at all fuel injectors. To install connector, refer to (Fig. 27). Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 11. Connect vacuum lines to throttle body. 12. Connect fuel line latch clip and fuel line to fuel rail. Refer to Quick-Connect Fittings. 13. Connect wiring to rear of generator. 14. Install air box to throttle body. 15. Install air duct to air box. 16. Connect battery cable to battery. 17. Start engine and check for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service Precautions Fuel Return Line: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service Precautions > Page 2791 Fuel Return Line: Description and Operation Also refer to Quick-Connect Fittings. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service Precautions Fuel Supply Line: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service Precautions > Page 2795 Fuel Supply Line: Description and Operation Also refer to Quick-Connect Fittings. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2800 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 % of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 % of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2801 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges under Electrical for Fuel Gauge testing. To test the gauge sending unit only it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2802 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector (Fig. 3). b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2803 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch (Fig. 5). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab (Fig. 6) to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2804 module is located inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Cut Valve > Component Information > Locations Fuel Tank Cut Valve: Locations Fig. 31 Rollover Valve Location (2-Door Models) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Cut Valve > Component Information > Locations > Page 2808 Fig. 32 Rollover Valve Locations (4-Door Models) This fuel tank check valve is located on the top of the fuel tank. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Cut Valve > Component Information > Locations > Page 2809 Fuel Tank Cut Valve: Description and Operation Fig. 31 Rollover Valve Location (2-Door Models) Fig. 32 Rollover Valve Locations (4-Door Models) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Cut Valve > Component Information > Locations > Page 2810 FUEL TANK CHECK VALVE The fuel tank on 2 door models is equipped with 1 fuel tank check valve. This valve is located on the top of the fuel tank (Fig. 31). The fuel tank on 4-door models is equipped with 2 fuel tank check valves. These valves are also located on the top of the fuel tank (Fig. 32). The fuel tank check valve(s) will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover. The EVAP canister draws fuel vapors from the fuel tank through this valve(s). The valve(s) cannot be serviced separately. If replacement is necessary the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Cut Valve > Component Information > Locations > Page 2811 Fuel Tank Cut Valve: Service and Repair REMOVAL The fuel tank check valves(s) are/is molded into the fuel tank and are not serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. INSTALLATION The fuel tank check valves(s) are/is molded into the fuel tank and are not serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Engine Speed Governor > Component Information > Locations Engine Speed Governor: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Engine Speed Governor > Component Information > Locations > Page 2815 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications Torque Torque IAC Motor-To-Throttle Body Bolts 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2819 Idle Air Control (IAC) Motor: Locations The IAC motor is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2820 Idle Air Control Motor (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2821 Idle Air Control (IAC) Motor: Description and Operation The IAC stepper motor is mounted to the throttle body and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: - Off-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC step-per motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the IAC motor through the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2822 Idle Air Control (IAC) Motor: Service and Repair REMOVAL The IAC motor is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect electrical connector from IAC motor. Fig. 62 TPS Mounting Bolts - 3.9/5.2/5.9L Engines 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2826 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2827 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2828 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2829 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2830 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2831 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2832 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2837 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2838 Fuel Pump Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2839 Fuel Pump Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2840 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2841 Fuel Pump Relay: 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, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2842 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 2843 Fuel Pump Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2847 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2848 Auto Shut Down (ASD) Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2849 Automatic Shut Down Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2850 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2851 Auto Shut Down (ASD) Relay: 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 ± 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2852 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2853 Auto Shut Down (ASD) Relay: Service and Repair Fig.3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations Fig. 41 Rollover Valve Locations (2 - Door Models) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2857 Fig. 42 Rollover Valve Locations (4 - Door Models) The fuel tank on 2-door models is located on the top of the fuel tank (Fig. 41). The fuel tank on 4-door models is located on the top of the fuel tank (Fig. 42). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2858 Rollover Valve: Description and Operation Fig. 41 Rollover Valve Locations (2 - Door Models) Fig. 42 Rollover Valve Locations (4 - Door Models) ROLLOVER VALVE The fuel tank on 2-door models is equipped with 1 rollover valve. This valve is located on the top of the fuel tank (Fig. 41). The fuel tank on Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2859 4-door models is equipped with 2 rollover valves. These valves are also located on the top of the fuel tank (Fig. 42). The rollover valve(s) will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover. The EVAP canister draws fuel vapors from the fuel tank through this valve(s). The valve(s) cannot be serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2860 Rollover Valve: Service and Repair REMOVAL The rollover valves(s) are/is molded into the fuel tank and are not serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. INSTALLATION The rollover valves(s) are/is molded into the fuel tank and are not serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2865 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2866 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2867 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2868 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2869 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2870 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations The throttle body is located on the intake manifold. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2874 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2875 Throttle Body: Service and Repair REMOVAL 1. Remove the air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect throttle body electrical connectors at IAC motor and TPS (Fig. 56). 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to Accelerator Pedal and Throttle Cable. 5. Remove three throttle body mounting bolts (Fig. 56). 6. Remove throttle body from intake manifold. INSTALLATION 1. Clean throttle body-to-intake manifold O-ring. 2. Clean mating surfaces of throttle body and intake manifold. 3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins. 4. Install three mounting bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body. 7. Install electrical connectors. 8. Install air duct/air box at throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions Throttle Cable/Linkage: Service Precautions CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal or cables. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 2879 Throttle Cable/Linkage: Service and Repair REMOVAL CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or throttle cable. Fig. 22 A/C Compressor Support 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of pedal arm (Fig. 22). Plastic cable retainer (clip) snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. From inside vehicle, remove clip holding cable to dash panel (Fig. 22). 4. Remove air box at throttle body. 5. Unsnap cable from dashpanel routing clip. 6. Remove cable housing from dash panel and pull into engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 2880 Fig. 60 Accelerator Cable At Bell Crank - 4.7L V-8 Engine 7. Using finger pressure only disconnect accelerator cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle (Fig. 60). DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. 8. Lift accelerator cable from top of cable cam (Fig. 60). Fig. 61 Accelerator Cable Release Tab - 4.7L V-8 Engine 9. Press tab (Fig. 61) to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount (Fig. 61) towards passenger side of vehicle to remove cable from bracket. 10. Remove throttle cable from vehicle. INSTALLATION 1. Slide accelerator cable plastic mount into bracket. Continue sliding until tab (Fig. 61) is aligned to hole in mounting bracket. 2. Route accelerator cable over top of cable cam. 3. Connect cable end to throttle body bellcrank pin (snaps on rearward). 4. Slide rubber grommet away from plastic cable housing. 5. Install rubber grommet into dash panel until seated. 6. Push cable housing into rubber grommet and through opening in dash panel. 7. From inside vehicle, install clip holding cable to dashpanel (Fig. 22). 8. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm. 9. Push cable retainer (clip) into pedal arm opening until it snaps in place. 10. Snap cable into dashpanel routing clip. 11. Install air box to throttle body. 12. Before starting engine, operate accelerator pedal to check for any binding. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Torque Torque Throttle Position Sensor Mounting Screws 7 Nm 60 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2884 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2885 Throttle Position Sensor (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2886 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2887 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 56 Throttle Body, Sensors And Electrical Connectors - 4.7L V-8 Engine 2. Disconnect TPS electrical connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2888 Fig. 63 TPS Mounting Bolts - 4.7L V-8 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 66 TPS Installation - 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2889 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2895 right front side of the engine block (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2896 Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2904 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2905 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2906 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2907 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2908 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2912 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2913 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2914 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2915 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2916 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service Precautions Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil Resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 2924 Ignition Coil: Mechanical Specifications Ignition Coil Mounting Nut ................................................................................................................... ...................................................... 8 Nm (70 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2925 Ignition Coil: Locations 4.7L Fig.23 Ignition Coil Location - 4.7L Engine Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2926 Ignition Coil: Diagrams Coil On Plug No.1 Coil On Plug No.2 Coil On Plug No.3 Coil On Plug No.4 Coil On Plug No.5 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2927 Coil On Plug No.6 Coil On Plug No.7 Coil On Plug No.8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2928 Ignition Coil: Description and Operation Fig.22 Ignition Coil - 4.7L Engine Fig.23 Ignition Coil Location - 4.7L Engine This engine uses 8 dedicated, and individually fired coil for each spark plug. Each coil is mounted directly to the top of each spark plug. Battery voltage is supplied to the 8 ignition coils from the ASD relay The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation. Base ignition timing is not adjustable. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2929 Because of coil design, spark plug cables (secondary cables) are not used. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2930 Ignition Coil: Service and Repair REMOVAL Fig.26 Ignition Coil - 4.7L V-8 Engine Fig.27 Ignition Coil Location - 4.7L V-8 Engine An individual ignition coil is used for each spark plug. The coil fits into machined holes in the cylinder head. A mounting stud/nut secures each coil to the top of the intake manifold. The bottom of the coil is equipped with a rubber boot to seal the spark plug to the coil. Inside each rubber boot is a spring. The spring is used for a mechanical contact between the coil and the top of the spark plug. These rubber boots and springs are a permanent part of the coil and are not serviced separately An O-ring is used to seal the coil at the opening into the cylinder head. 1. Depending on which coil is being removed, the throttle body air intake tube or intake box may need to be removed to gain access to coil. 2. Disconnect electrical connector from coil by pushing downward on release lock on top of connector and pull connector from coil. 3. Clean area at base of coil with compressed air before removal. 4. Remove coil mounting nut from mounting stud. 5. Carefully pull up coil from cylinder head opening with a slight twisting action. 6. Remove coil from vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2931 INSTALLATION 1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. 2. Check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 3. Position ignition coil into cylinder head opening and push onto spark plug. Do this while guiding coil base over mounting stud. 4. Install mounting stud nut and tighten to 8 Nm (70 in. lbs.) torque. 5. Connect electrical connector to coil by snapping into position. 6. If necessary, install throttle body air tube or box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ............................................................................................................ .................................................... 12 Nm (106 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2936 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2937 Camshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2938 Camshaft Position Sensor: Description and Operation Fig.4 CMP Location - 4.7L Engine The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig.5 CMP Sensor And Tonewheel - 4.7L Engine The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2939 differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinder Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2940 Camshaft Position Sensor: Service and Repair Fig.7 CMP Location - 4.7L Engine REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder head. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs) torque 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .......................................................................................................... ...................................................... 28 Nm (21 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2944 Crankshaft Position Sensor: Locations Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2945 Crankshaft Position Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2946 Crankshaft Position Sensor: Description and Operation Fig. 24 CKP Sensor Location - 4.7L V-8 Engine The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2947 Fig. 28 CKP Sensor Operation And Tonewheel - 4.7L V-8 Engine On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2948 Crankshaft Position Sensor: Service and Repair Fig. 31 CKP Sensor Location/Removal/Installation - 4.7L V-8 Engine REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully twist sensor from cylinder block. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 2953 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Torque ................................................................................................................................................. ....................................................... 27 Nm (20 ft. lbs) Plug Type ............................................................................................................................................ .............................................................. RC12MCC4 Electrode Gap ...................................................................................................................................... ................................................... 1.01 mm (0.040 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2957 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2958 Spark Plug: Description and Operation All engines use resistor type spark plugs. This engine is equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2959 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig.28 Normal Operation And Cold (Carbon) Fouling Normal Operating The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. On all engines except the 4.7L V-8, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. On the 4.7L V-8, gap growth will not average more than approximately 0.0015 in per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2960 Fig.29 Oil Or Ash Encrusted Oil or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.30 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2961 Fig.31 Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig.32 Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2962 Fig.33 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig.34 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2963 Spark Plug: Service and Repair REMOVAL Fig.35 Heat Shields - 3.9/5.2/5.9L Engines On 3.9L V-6 and 5.2/5.9L V-8 engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 4.7L V-8 Engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. Except 4.7L Engine: Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. 4.7L V-8 Engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 3. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition of coil O-ring and replace as necessary. Fig.37 Cable Removal 4. Except 4.7L: Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 5. Inspect spark plug condition. Refer to Spark Plug Conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2964 CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: The 4.7L V-8 engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. Except 4.7L Engine: When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Except 4.7L Engine: Tighten spark plugs to 35 - 41 Nm (26-30 ft. lbs.) torque. 3. Except 4.7L Engine: Install spark plug cables over spark plugs. 4. 4.7L V-8 Engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 5. 4.7L V-8 Engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 6. 4.7L V-8 Engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Pressure Regulating Solenoid: Description and Operation Solenoid Switch Valve / 45RFE - Automatic Transmission DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Shift Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2980 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2981 Shift Solenoid: Description and Operation TRANSMISSION SOLENOID/ TRS ASSEMBLY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 116). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION - SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES 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 chart: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2982 L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2983 Shift Solenoid: Service and Repair Transmission Solenoid/TRS Assembly / 45RFE - Automatic Transmission REMOVAL 1. Remove the valve body from the transmission (Fig. 117). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 118). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations > Page 2991 Transfer Case Shift Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Shift Motor: Description and Operation NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 78) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case > Page 2994 Transfer Case Shift Motor: Description and Operation NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 85) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case Transfer Case Shift Motor: Service and Repair NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 79) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 80) 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 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 2997 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to .........122 - 176 Nm (90 -130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 2998 Transfer Case Shift Motor: Service and Repair NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 86) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 87) 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 Lock & Seal or Loctite(tm) 242 to replenish Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 2999 the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3005 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3006 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3010 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Locations > Page 3015 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Locations > Page 3016 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3029 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3031 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3032 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3033 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3034 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3042 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3043 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3044 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3045 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3046 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3050 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3051 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3052 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3053 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3058 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3059 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3060 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3061 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3062 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3068 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3069 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3070 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3071 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3075 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3076 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3077 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3078 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3087 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3088 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3089 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3090 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3093 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3094 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3095 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3098 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3099 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3100 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3101 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3102 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3106 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3107 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3112 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3113 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3114 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3117 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3120 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 3128 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 3131 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 3132 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 3133 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 3137 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 3140 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 3141 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 3142 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 PROM - Programmable Read Only Memory: Customer Interest Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 NUMBER: 18-002-03 GROUP: Vehicle Performance DATE: Jan. 31, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-016-02 REV A, DATED SEPTEMBER 23, 2002, WHICH SHOULD BE REM9VED FROM YOUR FILES. THE REVISION IS HIGHLIGHTED WITH **ASTERISK** AND INCLUDES AN ADDITIONAL MODEL YEAR FOR THE WJ VEHICLES. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2126 OR HIGHER, AVAILABLE FEBRUARY 17, 2003. SUBJECT: Flash: MIL Illumination For Erroneous DTC P0456 - EVAP Monitor Small Leak Detected OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002 (AN) Dakota 2002 (DN) Durango **2002** - (WJ) Grand Cherokee 2003 NOTE: THIS BULLETIN APPLIES TO 2002 (AN) DAKOTA AND (DN) DURANGO EQUIPPED WITH ANY CORPORATE ENGINE AND, **2002** - 2003 (WJ) EQUIPPED WITH THE 4.7L ENGINE (SALES CODE EVA OR EVC). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to the erroneous detection of a small leak in the vehicle's evaporative system. The Diagnosis Trouble Code (DTC) associated with this condition is P0456 (EVAP Monitor Small Leak Detected.) No system leaks are detected when the evaporative system is tested. The DTC may be intermittent. DIAGNOSIS: If MIL is on and Diagnostic Trouble Code (DTC) P0456 is present, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 > Page 3151 1. Connect a battery charger and set as close to a 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 > Page 3152 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3158 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3159 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3160 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3161 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3162 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3163 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3164 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3165 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3166 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3167 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3168 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3169 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3170 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3171 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3172 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3173 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3174 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3175 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3176 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 NUMBER: 18-002-03 GROUP: Vehicle Performance DATE: Jan. 31, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-016-02 REV A, DATED SEPTEMBER 23, 2002, WHICH SHOULD BE REM9VED FROM YOUR FILES. THE REVISION IS HIGHLIGHTED WITH **ASTERISK** AND INCLUDES AN ADDITIONAL MODEL YEAR FOR THE WJ VEHICLES. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2126 OR HIGHER, AVAILABLE FEBRUARY 17, 2003. SUBJECT: Flash: MIL Illumination For Erroneous DTC P0456 - EVAP Monitor Small Leak Detected OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002 (AN) Dakota 2002 (DN) Durango **2002** - (WJ) Grand Cherokee 2003 NOTE: THIS BULLETIN APPLIES TO 2002 (AN) DAKOTA AND (DN) DURANGO EQUIPPED WITH ANY CORPORATE ENGINE AND, **2002** - 2003 (WJ) EQUIPPED WITH THE 4.7L ENGINE (SALES CODE EVA OR EVC). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to the erroneous detection of a small leak in the vehicle's evaporative system. The Diagnosis Trouble Code (DTC) associated with this condition is P0456 (EVAP Monitor Small Leak Detected.) No system leaks are detected when the evaporative system is tested. The DTC may be intermittent. DIAGNOSIS: If MIL is on and Diagnostic Trouble Code (DTC) P0456 is present, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 > Page 3181 1. Connect a battery charger and set as close to a 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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: > 18-002-03 > Jan > 03 > Engine Controls/Emissions - MIL ON/Erroneous DTC P0456 > Page 3182 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3188 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3189 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3190 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3191 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3192 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3193 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3194 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3195 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3196 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3197 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3198 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3199 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3200 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3201 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3202 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3203 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3204 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3205 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3206 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Pressure Regulating Solenoid: Description and Operation Solenoid Switch Valve / 45RFE - Automatic Transmission DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3222 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3223 Shift Solenoid: Description and Operation TRANSMISSION SOLENOID/ TRS ASSEMBLY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 116). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION - SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES 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 chart: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3224 L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3225 Shift Solenoid: Service and Repair Transmission Solenoid/TRS Assembly / 45RFE - Automatic Transmission REMOVAL 1. Remove the valve body from the transmission (Fig. 117). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 118). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations > Page 3233 Transfer Case Shift Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Shift Motor: Description and Operation NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 78) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case > Page 3236 Transfer Case Shift Motor: Description and Operation NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 85) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case Transfer Case Shift Motor: Service and Repair NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 79) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 80) 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 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 3239 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to .........122 - 176 Nm (90 -130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 3240 Transfer Case Shift Motor: Service and Repair NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 86) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 87) 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 Lock & Seal or Loctite(tm) 242 to replenish Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 3241 the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation Solenoid Switch Valve / 45RFE - Automatic Transmission DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3256 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3257 Shift Solenoid: Description and Operation TRANSMISSION SOLENOID/ TRS ASSEMBLY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 116). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION - SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES 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 chart: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3258 L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3259 Shift Solenoid: Service and Repair Transmission Solenoid/TRS Assembly / 45RFE - Automatic Transmission REMOVAL 1. Remove the valve body from the transmission (Fig. 117). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 118). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Band: Description and Operation 42RE (A-500) 4 Speed 42RE - Automatic Transmission DESCRIPTION KICKDOWN (FRONT) BAND The kickdown, or "front", band (Fig. 63) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining. One end of the band is anchored to the transmission case, and the other is acted on with a pushing force by a servo piston. The front band is a single-wrap design (the band does not completely encompass/ wrap the drum that it holds). LOW/REVERSE (REAR) BAND The low/reverse band, or "rear", band (Fig. 64) is similar in appearance and operation to the front band. The rear band is slightly different in that it does not use a link bar, but is acted directly on by the apply lever. This is referred to as a double-wrap band design (the drum is completely encompassed/ wrapped by the band). The double-wrap band provides a greater holding power in comparison to the single-wrap design. OPERATION KICKDOWN (FRONT) BAND Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3270 The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front clutch retainer, which is splined to the sun gear driving shell, and in turn splined directly to the sun gear. The application of the band by the servo is typically done by an apply lever and link bar. LOW/REVERSE (REAR) BAND The rear band holds the rear planet carrier stationary by being mounted around and applied to the low/reverse drum. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3271 Band: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission DESCRIPTION KICKDOWN (FRONT) BAND The kickdown, or "front", band (Fig. 70) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining. One end of the band is anchored to the transmission case, and the other is acted on with a pushing force by a servo piston. The front band is a single-wrap design (the band does not completely encompass/ wrap the drum that it holds). LOW/REVERSE (REAR) BAND The low/reverse band, or "rear", band (Fig. 71) is similar in appearance and operation to the front band. The rear band is also a single-wrap design (the band does not completely encompass/wrap the drum that it holds). OPERATION KICKDOWN (FRONT) BAND The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front clutch retainer, which is splined to the sun gear driving shell, and in turn splined directly to the sun gear. The application of the band by the servo is typically done by an apply lever and link bar. LOW/REVERSE (REAR) BAND The rear band holds the rear planet carrier stationary by being mounted around and applied to the low/reverse drum. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications 2C Clutch Pack Clearance 0.021 - 0.050 in 4C Clutch Pack Clearance 0.032 - 0.053 in UR Clutch Pack Clearance 0.045 - 0.075 in OD Clutch Pack Clearance 0.040 - 0.065 in UD Clutch Pack Clearance 0.030 - 0.063 in Reverse Clutch Pack Clearance 0.032 - 0.049 in Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3278 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch Clutch: Description and Operation Holding Clutch 45RFE - AUTOMATIC TRANSMISSION HOLDING CLUTCH / DESCRIPTION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3281 Three hydraulically applied multi-disc clutches are used to hold some planetary geartrain components stationary while the input clutches drive others. The 2C, 4C, and Low/Reverse clutches are considered holding clutches. The 2C and 4C clutches are located in the 4C retainer/bulkhead (Fig. 65), while the Low/ Reverse clutch is located at the rear of the transmission case (Fig. 66). OPERATION 2C CLUTCH The 2C clutch is hydraulically applied in second gear by pressurized fluid against the 2C piston. When the 2C clutch is applied, the reverse sun gear assembly is held or grounded to the transmission case by holding the reaction planetary carrier. 4C CLUTCH The 4C clutch is hydraulically applied in second prime and fourth gear by pressurized fluid against the 4C clutch piston. When the 4C clutch is applied, the reaction annulus gear is held or grounded to the transmission case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gear, only at low speeds, by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the input annulus assembly is held or grounded to the transmission case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3282 Clutch: Description and Operation Input Clutch 45RFE - AUTOMATIC TRANSMISSION INPUT CLUTCH / DESCRIPTION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3283 Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 67) and (Fig. 68). The input clutch assembly also contains: - Input shaft - Input hub - Clutch retainer - Underdrive piston - Overdrive/reverse piston - Overdrive hub - Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, second prime, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the input sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and fourth gears by pressurized fluid against the overdrive/reverse piston. When the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3284 overdrive clutch is applied, the overdrive hub drives the reverse carrier/input annulus assembly. REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the reaction annulus gear is driven. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch Clutch: Service and Repair Input Clutch Disassembly 45RFE - AUTOMATIC TRANSMISSION INPUT CLUTCH / DISASSEMBLY 1. Remove the reverse reaction plate selective snap-ring from the input clutch retainer (Fig. 69). 2. Remove the reverse reaction plate from the input clutch retainer. 3. Remove the reverse hub and reverse clutch pack from the input clutch retainer. 4. Remove the number 4 bearing from the overdrive hub. 5. Remove the overdrive hub from the input clutch retainer (Fig. 69). 6. Remove the number 3 bearing from the underdrive hub. 7. Remove the OD/reverse reaction plate snapring from the input clutch retainer. 8. Remove the underdrive hub, overdrive clutch, and overdrive reaction plate from the input clutch retainer (Fig. 69). NOTE: The overdrive friction discs and steel discs are thicker than the matching components in the underdrive and reverse clutches. 9. Remove the number 2 bearing from the input clutch hub. 10. Remove the overdrive clutch wave snap-ring from the input clutch retainer. 11. Remove the UD/OD reaction plate tapered snap-ring from the input clutch retainer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3287 12. Remove the UD/OD reaction plate from the input clutch retainer. 13. Remove the UD/OD reaction plate flat snapring from the input clutch retainer (Fig. 69). 14. Remove the underdrive clutch pack from the input clutch retainer (Fig. 71). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3288 15. Using Spring Compressor 8251, compress the UD/OD balance piston and remove the snap-ring from the input clutch hub (Fig. 70). 16. Remove the UD/OD balance piston and piston return spring from the input clutch retainer (Fig. 71). 17. Remove the underdrive piston from the input clutch retainer (Fig. 71). NOTE: Both the UD/OD balance piston and the underdrive piston have seals molded onto them. If the seal is damaged, do not attempt to install a new seal onto the piston. The piston/seal must be replaced as an assembly. 18. Remove the input clutch retainer tapered snap-ring. 19. Separate input clutch retainer from input clutch hub. 20. Separate OD/reverse piston from input clutch hub retainer (Fig. 71). 21. Remove all seals and O-rings from the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to make note of which O-ring belongs in which location. Assembly 45RFE - AUTOMATIC TRANSMISSION INPUT CLUTCH / ASSEMBLY 1. Install all new seals and O-rings onto the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to install the correct O-ring in the correct location. 2. Check the transmission lubrication check valve located in the input shaft using shop air. The valve should only allow air flow in one direction. If the valve allows no air flow, or air flow in both directions, the valve will need to be replaced. 3. Lubricate all seals with Mopar ATF +4, type 9602, prior to installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3289 4. Assemble the OD/reverse piston onto the input clutch hub (Fig. 72). 5. Assemble the input clutch retainer onto the input clutch hub. 6. Install the input clutch retainer tapered snapring with tapered side up onto the input clutch hub. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3290 7. Install Piston Guides 8504 into the input clutch retainer (Fig. 73) and onto the input clutch hub to guide the inner and outer underdrive piston seals into position. 8. Install the underdrive piston into the input clutch retainer and over the input clutch hub (Fig. 72). 9. Install the UD/OD balance piston return spring pack into the input clutch retainer. 10. Install Piston Guide 8252 into the input clutch retainer (Fig. 74) to guide the UD/OD balance piston seal into position inside the underdrive piston. 11. Install the UD/OD balance piston into the input clutch retainer and the underdrive piston. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3291 12. Using Spring Compressor 8251, compress the UD/OD return spring pack and secure the piston in place with the snap-ring (Fig. 75). 13. Install the underdrive clutch pack into the input clutch retainer (Fig. 72). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3292 14. Install the UD/OD reaction plate lower flat snap-ring (Fig. 76). The correct snap-ring can be identified by the two tabbed ears. 15. Install the UD/OD reaction plate into the input clutch retainer. The reaction plate is to be installed with the big step down. 16. Install the UD/OD reaction plate upper tapered snap-ring with tapered side up. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3293 17. Install the input clutch assembly into Input Clutch Pressure Fixture 8260 (Fig. 77). Mount a dial indicator to the assembly, push down on the clutch discs and zero the indicator against the underdrive clutch discs (Fig. 78). Apply 20 psi of air pressure to the underdrive clutch and record the dial indicator reading. Measure and record UD clutch pack measurement in four places, 90° apart. Take average of four measurements and compare with UD clutch pack clearance specification. The correct clutch clearance is 0.84 - 1.54 mm (0.033 - 0.061 inch). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs. 18. Install the overdrive clutch pack into the input clutch retainer (Fig. 76). The overdrive steel separator plates can be identified by the lack of the half-moon cuts in the locating tabs. 19. Install the overdrive clutch wavy snap-ring with the two tabbed ears into the input clutch retainer. 20. Install the OD/reverse reaction plate into the input clutch retainer. The reaction plate is non-directional (Fig. 76). 21. Install the OD/reverse reaction plate flat snap-ring into the input clutch retainer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3294 22. Mount a dial indicator to the assembly and zero the indicator against the OD/reverse reaction plate (Fig. 79). Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator reading. Measure and record OD clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with OD clutch pack clearance specification. Verify that the clutch clearance is 1.103 - 1.856 mm (0.043 - 0.073 inch). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs. 23. Install the reverse clutch pack into the input clutch retainer (Fig. 76). 24. Install the reverse reaction plate into the input clutch retainer. 25. Install the reverse reaction plate selective snap-ring into the input clutch retainer. 26. Mount a dial indicator to the assembly, push down on the clutch discs, pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against the reverse clutch discs (Fig. 80). Apply 20 psi of air pressure to the reverse clutch and record the dial indicator reading. Measure and record Reverse clutch pack measurement in four places, 90° apart. Take an average of four measurements, and compare with reverse clutch pack clearance specification. The correct clutch clearance is 0.58 - 1.47 mm (0.023 0.058 inch). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection. 27. Remove the reverse clutch pack from the input clutch retainer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3295 28. Install the number 2 bearing onto the underdrive hub with outer race against the hub with petroleum jelly. 29. Install the underdrive hub into the input clutch retainer. 30. Install the number 3 bearing into the overdrive hub with the outer race against the hub with petroleum jelly. 31. Install the overdrive hub into the input clutch retainer. 32. Install the number 4 bearing into the reverse hub with outer race against the hub with petroleum jelly. 33. Install the reverse hub into the input clutch retainer. 34. Install the complete reverse clutch pack. 35. Install the reverse reaction plate and snapring. 36. Push up on reaction plate to allow reverse clutch to move freely. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3296 Clutch: Service and Repair Low / Reverse Clutch Disassembly 45RFE - AUTOMATIC TRANSMISSION LOW-REVERSE CLUTCH / DISASSEMBLY 1. Remove the inner overrunning clutch snap-ring from the low/reverse clutch retainer (Fig. 83). 2. Remove the outer low/reverse reaction plate flat snap-ring (Fig. 83). 3. Remove the low/reverse clutch and the overrunning clutch from the low/reverse clutch retainer as an assembly (Fig. 83). 4. Separate the low/reverse clutch from the overrunning clutch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3297 5. Remove the overrunning clutch snap-ring (Fig. 84). 6. Remove the spacer from the overrunning clutch (Fig. 84). 7. Separate the inner and outer races of the overrunning clutch (Fig. 84). 8. Remove the overrunning clutch lower snap-ring (Fig. 84). 9. Using Spring Compressor 8285 and a suitable shop press (Fig. 85), compress the low/reverse piston Belleville spring and remove the split retaining ring holding the Belleville spring into the low/reverse clutch retainer. 10. Remove the low/reverse clutch Belleville spring and piston from the low/reverse clutch retainer. Use 20 psi of air pressure to remove the piston if necessary. Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION LOW-REVERSE CLUTCH / CLEANING Clean the overrunning clutch assembly, clutch cam, and low-reverse clutch retainer. Dry them with compressed air after cleaning. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3298 INSPECTION Inspect condition of each clutch part after cleaning. Replace the overrunning clutch roller and spring assembly if any rollers or springs are worn or damaged, or if the roller cage is distorted, or damaged. Replace the cam if worn, cracked or damaged. Replace the low-reverse clutch retainer if the clutch race, roller surface or inside diameter is scored, worn or damaged. Assembly Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3299 45RFE - AUTOMATIC TRANSMISSION LOW-REVERSE CLUTCH / ASSEMBLY 1. Check the bleed orifice to ensure that it is not plugged or restricted. 2. Install a new seal on the low/reverse piston. Lubricate the seal with Mopar ATF +4, type 9602, prior to installation. 3. Install the low/reverse piston into the low/reverse clutch retainer. 4. Position the low/reverse piston Belleville spring on the low/reverse piston. 5. Using Spring Compressor 8285 and a suitable shop press (Fig. 85), compress the low/reverse piston Belleville spring and install the split retaining ring to hold the Belleville spring into the low/reverse clutch retainer. 6. Install the lower overrunning clutch snap-ring (Fig. 84). 7. Assemble the inner and outer races of the overrunning clutch (Fig. 84). 8. Position the overrunning clutch spacer on the overrunning clutch. 9. Install the upper overrunning clutch snap-ring (Fig. 84). 10. Assemble and install the low/reverse clutch pack into the low/reverse clutch retainer (Fig. 83). 11. Install the low/reverse reaction plate into the low/reverse clutch retainer (Fig. 83). The reaction plate is directional and must be installed with the flat side down. 12. Install the low/reverse clutch pack snap-ring (Fig. 83). The snap-ring is selectable and should be chosen to give the correct clutch pack clearance. 13. Measure the low/reverse clutch pack clearance and adjust as necessary. The correct clutch clearance is 1.00 - 1.74 mm (0.039 - 0.075 inch). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3300 14. Install the overrunning clutch into the low/reverse clutch retainer making sure that the index splines are aligned with the retainer. 15. Install the overrunning clutch inner snapring. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3301 Clutch: Service and Repair 4C Retainer / Bulkhead Disassembly 45RFE Automatic Transmission 4C RETAINER/BULKHEAD - DISASSEMBLY 1. Remove the 2C piston belleville spring snapring from the 4C retainer /bulkhead (Fig. 50). 2. Remove the 2C piston Belleville spring from the retainer/bulkhead (Fig. 50). 3. Remove the 2C piston from the retainer/bulkhead. Use 20 psi of air pressure to remove the piston if necessary. 4. Remove the 4C clutch snap-ring from the retainer/bulkhead (Fig. 50). 5. Remove the 4C clutch pack from the retainer/ bulkhead (Fig. 50). 6. Using Spring Compressor 8250 and a suitable shop press, compress the 4C piston return spring and remove the snap-ring (Fig. 50). 7. Remove the 4C piston return spring and piston from the retainer/bulkhead (Fig. 50). Use 20 psi of air pressure to remove the piston if necessary. Assembly 45RFE Automatic Transmission 4C RETAINER/BULKHEAD - ASSEMBLY 1. Clean and inspect all components. Replace any components, which show evidence of excessive wear or scoring. 2. Install new seals on the 2C and 4C pistons (Fig. 50). 3. Lubricate all seals with Mopar ATF +4, type 9602 prior to installation. 4. Install the 4C piston into the 4C retainer/bulkhead (Fig. 50). 5. Position the 4C piston return spring onto the 4C piston. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3302 6. Using Spring Compressor 8250 and a suitable shop press, compress the 4C piston return spring and install the snap-ring (Fig. 51). 7. Assemble and install the 4C clutch pack into the retainer/bulkhead (Fig. 50) with the steel separator plate against the piston. 8. Install the 4C reaction plate and snap-ring into the retainer/bulkhead (Fig. 50). The 4C reaction plate is non-directional. 9. Measure the 4C clutch clearance. The correct clutch clearance is 0.77 - 1.39 mm (0.030 - 0.055 inch). The snap-ring is selectable. Install the chosen snapring and re-measure to verify the selection. 10. Install the 2C piston into the retainer/bulkhead (Fig. 50). 11. Position the 2C Belleville spring onto the 2C piston. 12. Position the 2C Belleville spring snap-ring onto the 2C Belleville spring (Fig. 50). 13. Using Spring Compressor 8249 and a suitable shop press (Fig. 52), compress the Belleville spring until the snap-ring is engaged with the snap-ring groove in the retainer/bulkhead. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3326 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3327 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3328 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3329 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3330 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Bolt, Extension Housing 40 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 3334 Extension Housing: Service and Repair 45RFE - Automatic Transmission ADAPTER HOUSING SEAL / REMOVAL 1. Remove the transfer case from the transmission. 2. Using a screw mounted on a slide hammer, remove the adapter housing seal. INSTALLATION 1. Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the adapter housing using Seal Installer C-3860-A (Fig. 53). A properly installed seal is flush to the face of the seal bore. 3. Install the transfer case onto the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3339 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3340 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 42RE (A-500) 4 Speed 42RE - Automatic Transmission Service Fill ....................................................................................... .......................................................................................................... 3.8Liters (4.0 Qt) O-haul Fill ..... .............................................................................................................................................................. ................. 9.1 - 9.5Liters (19 - 20 Pt) 45RFE 4 Speed 45RFE - Automatic Transmission Service Fill 2WD .................................................................................................................................. .................................................... 5.2Liters (11.0 Pt) Service Fill 4WD .................................................................................................................................. .................................................... 6.2Liters (13.0 Pt) O-haul Fill ............................................................................................................................................ ................................................. 13.33Liters (28.0 Pt) 46RE (A-518) 4 Speed 46RE - Automatic Transmission Service Fill ........................................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) O-Haul Fill ............................................................................................................................................ ....................................... 9.1 - 9.5Liters (19 - 20 Pt) NOTE: Dry fill capacity depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3343 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 NOTE:Dextron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3344 Fluid - A/T: Service Precautions CAUTION: Never overfill the automatic transmission. Foaming and loss of fluid through the vent or filler tube, and malfunction, may result. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3345 Fluid - A/T: Description and Operation The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - 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 build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3348 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3349 Fluid - A/T: Testing and Inspection Fluid Contamination 45RFE - AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3350 Fluid - A/T: Testing and Inspection Standard Procedures 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DABS scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. (Fig. 56) 9. Adjust transmission fluid level shown on the dipstick according to the chart. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3351 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fill Fluid - A/T: Service and Repair Transmission Fill 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - 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 ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 3354 Fluid - A/T: Service and Repair Removal 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 57). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 3355 Fluid - A/T: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fill > Page 3356 Fluid - A/T: Service and Repair Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 57). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4, type 9602 fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3365 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3371 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 3372 Fluid Filter - A/T: Specifications Screws, Fluid Filter 35 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Removal Fluid Filter - A/T: Service and Repair Removal 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 57). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 3375 Fluid Filter - A/T: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 3376 Fluid Filter - A/T: Service and Repair Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 57). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4, type 9602 fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Removal > Page 3377 Fluid Filter - A/T: Service and Repair Transmission Fill 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - 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 ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Fitting, Cooler Line At Trans 13 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 3381 Fluid Line/Hose: Service and Repair FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906-B Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906-B. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906-B. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar ATE +4, type 9602, Automatic Transmission Fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications 42RE - Automatic Transmission Bolt, fluid pan ....................................................................................................................................... .................................................... 17 Nm (13 ft lbs) 46RE - Automatic Transmission Bolt, fluid pan ....................................................................................................................................... .................................................... 34 Nm (25 ft lbs) 45RFE - Automatic Transmission Bolt, oil pan .......................................................................................................................................... ............................................... 11.8 Nm (105 in lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Removal Fluid Pan: Service and Repair Removal 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 57). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Removal > Page 3387 Fluid Pan: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Removal > Page 3388 Fluid Pan: Service and Repair Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 57). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4, type 9602 fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Removal > Page 3389 Fluid Pan: Service and Repair Transmission Fill 45RFE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - 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 ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3393 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3394 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3395 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3396 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Bolt, Oil Pump 250 in.lb Bolt, Oil Pump Body To Cover 40 in.lb Screw, Plate To Oil Pump Body 40 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3400 Fluid Pump: Description and Operation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3401 45RFE - AUTOMATIC TRANSMISSION DESCRIPTION - OIL PUMP The oil pump (Fig. 86) is located at the front of the transmission inside the bell housing and behind the transmission front cover. The oil pump consists of two independent pumps (Fig. 87), a number of valves (Fig. 88), a front seal (Fig. 89), and a bolt on reaction shaft. The converter clutch switch and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3402 regulator valves, pressure regulator valve, and converter pressure limit valve are all located in the oil pump valve body. OPERATION As the torque converter rotates, the converter hub rotates the oil pump drive gear. As the drive gear rotates both driven gears, a vacuum is created when the gear teeth come out of mesh. This suction draws fluid through the pump inlet from the oil pan. As the gear teeth come back into mesh, pressurized fluid is forced into the pump outlet and to the oil pump valves. At low speeds, both sides of the pump supply fluid to the transmission. As the speed of the torque converter increases, the flow from both sides increases until the flow from the primary side alone is sufficient to meet system demands. At this point, the check valve located between the two pumps closes. The secondary side is shut down and the primary side supplies all the fluid to the transmission. CONVERTER CLUTCH SWITCH VALVE The converter clutch switch valve is used to control the hydraulic pressure supplied to the front (OFF) side of the torque converter clutch. CONVERTER CLUTCH REGULATOR VALVE The converter clutch regulator valve is used to control the hydraulic pressure supplied to the back (ON) side of the torque converter clutch. TORQUE CONVERTER LIMIT VALVE The torque converter limit valve serves to limit the available line pressure to the torque converter clutch to approximately 120 psi. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3403 Fluid Pump: Testing and Inspection 45RFE - 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 ATF +4, type 9602, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. GCAUTION:With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5°C (220°F) for this test. 3. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. 4. Re-connect the To cooler line to the transmission cooler inlet. 5. Refill the transmission to proper level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly Fluid Pump: Service and Repair Disassembly 45RFE - AUTOMATIC TRANSMISSION OIL PUMP / DISASSEMBLY 1. Remove the bolts holding the reaction shaft support to the oil pump (Fig. 90). 2. Remove the reaction shaft support from the oil pump (Fig. 90). 3. Remove all bolts holding the oil pump halves together (Fig. 90). 4. Using suitable prying tools, separate the oil pump sections by inserting the tools in the supplied areas and prying the halves apart. NOTE: The oil pump halves are aligned to each other through the use of two dowels. Be sure to pry upward evenly to prevent damage to the oil pump components. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3406 5. Remove the screws holding the separator plate onto the oil pump body (Fig. 91). 6. Remove the separator plate from the oil pump body (Fig. 91). 7. Mark all gears for location. The gears are select fit and if the oil pump is to be reused, the gears must be returned to their original locations. 8. Remove the oil pump gears from the oil pump case (Fig. 91). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3407 9. Remove the oil pump valve retainers and associated valve and spring one at a time (Fig. 92) (Fig. 93). Mark the combination of components as a group and tag them as to the location from which they were removed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3408 Fluid Pump: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION OIL PUMP / CLEANING Clean pump and support components with solvent and dry them with compressed air. INSPECTION Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn. Inspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged. Inspect the pump reaction shaft support bushings. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually damaged. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the oil pump cover. Use a penlight to view the bore interiors. Replace the oil pump if any bores are distorted or scored. Inspect all of the valve springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3409 Fluid Pump: Service and Repair Assembly 45RFE - AUTOMATIC TRANSMISSION OIL PUMP / ASSEMBLY 1. Clean and inspect all components. Make sure that all passages are thoroughly cleaned and are free from dirt or debris. Make sure that all valves move freely in their proper bore. Make sure that all gear pockets and bushings are free from excessive wear and scoring. Replace the oil pump if any excessive wear or scoring is found. 2. Coat the gears with Mopar ATF +4, type 9602, and install into their original locations. 3. Lubricate the oil pump valves with Mopar ATF +4, type 9602, and install the valve, spring and retainer into the appropriate oil pump valve body bore (Fig. 92) (Fig. 93). 4. Place the separator plate onto the oil pump body (Fig. 91). 5. Install the screws to hold the separator plate onto the oil pump body (Fig. 91). Tighten the screws to 4.5 Nm (40 inch lbs.). 6. Position the oil pump cover onto the locating dowels (Fig. 90). 7. Seat the two oil pump halves together and install all bolts finger tight. 8. Torque all bolts down slowly starting in the center and working outward. The correct torque is 4.5 Nm (40 inch lbs.). 9. Verify that the oil pump gears rotate freely and smoothly. 10. Position the reaction shaft support into the oil pump (Fig. 90). 11. Install and torque the bolts to hold the reaction shaft support to the oil pump (Fig. 90). The correct torque is 12 Nm (105 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3413 Governor: Description and Operation 42RE - Automatic Transmission DESCRIPTION Governor pressure is controlled electronically. Components used for governor pressure control include: - Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle position sensor (TPS) - Transmission speed sensor - Powertrain control module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty-cycle solenoid, which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate (Fig. 69). GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve (Fig. 70). GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body. The body is bolted to the lower side of the transfer plate (Fig. 70). 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3414 The fourth curve is used when driving with the transfer case in low range. OPERATION Compensation is required for performance variations of two of the input devices. Though the slope of the transfer functions is tightly controlled, offset 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 bans control relay, which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump, to determine when low temperature governor pressure is needed. NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load condition. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears, occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. WIDE OPEN THROTTLE OPERATION In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. TRANSFER CASE LOW RANGE OPERATION On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares electronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3419 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3420 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3424 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed Output Shaft Bearing/Bushing: Service and Repair 42/44RE (A-500) 4 Speed Output Shaft Front Bearing 42RE - Automatic Transmission Output Shaft Front Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. 3. Remove snap-ring holding output shaft front bearing to overdrive geartrain. (Fig. 121). 4. Pull bearing from output shaft. INSTALLATION 1. Place replacement bearing in position on geartrain with locating retainer groove toward the rear. 2. Push bearing onto shaft until the snap-ring groove is visible. 3. Install snap-ring to hold bearing onto output shaft. 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Output Shaft Rear Bearing 42RE - Automatic Transmission Output Shaft Rear Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed > Page 3429 3. Remove snap-ring holding output shaft rear bearing into overdrive housing (Fig. 122). 4. Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION 1. Place replacement bearing in position in housing. 2. Using a suitable driver, drive bearing into housing until the snap-ring groove is visible. 3. Install snap-ring to hold bearing into housing (Fig. 122). 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed > Page 3430 Output Shaft Bearing/Bushing: Service and Repair 46RE (A-518) 4 Speed Output Shaft Front Bearing 46RE - Automatic Transmission Output Shaft Front Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. 3. Remove snap-ring holding output shaft front bearing to overdrive geartrain. (Fig. 124). 4. Pull bearing from output shaft. INSTALLATION 1. Place replacement bearing in position on geartrain with locating retainer groove toward the rear. 2. Push bearing onto shaft until the snap-ring groove is visible. 3. Install snap-ring to hold bearing onto output shaft. 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Output Shaft Rear Bearing 46RE - Automatic Transmission Output Shaft Rear Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed > Page 3431 3. Remove snap-ring holding output shaft rear bearing into overdrive housing (Fig. 125). 4. Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION 1. Place replacement bearing in position in housing. 2. Using a suitable driver, drive bearing into housing until the snap-ring groove is visible. 3. Install snap-ring to hold bearing into housing (Fig. 125). 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 3439 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 3440 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3444 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3445 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3446 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3447 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation Planetary Gears: Description and Operation 45RFE - AUTOMATIC TRANSMISSION PLANETARY GEARTRAIN / DESCRIPTION The planetary geartrain is located behind the 4C retainer/bulkhead, toward the rear of the transmission. The planetary geartrain consists of three primary assemblies: Reaction (Fig. 104). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > Page 3451 Reverse / Input (Fig. 105). OPERATION REACTION PLANETARY GEARTRAIN The reaction planetary carrier and reverse sun gear of the reaction planetary geartrain are a single component, which is held by the 2C clutch when required. The reaction annulus gear is a stand alone component that can be driven by the reverse clutch or held by the 4C clutch. The reaction sun gear is driven by the overdrive clutch. REVERSE PLANETARY GEARTRAIN The reverse planetary geartrain is the middle of the three planetary sets. The reverse planetary carrier can be driven by the overdrive clutch as required. The reverse planetary carrier is also splined to the input annulus gear, which can be held by the low/reverse clutch. The reverse planetary annulus, input planetary carrier, and output shaft are all one piece. INPUT PLANETARY GEARTRAIN The input sun gear of the input planetary geartrain is driven by the underdrive clutch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly Planetary Gears: Service and Repair Disassembly 45RFE - AUTOMATIC TRANSMISSION PLANETARY GEARTRAIN / DISASSEMBLY 1. Remove the snap-ring holding the input annulus into the input carrier (Fig. 106). 2. Remove the input annulus from the input carrier (Fig. 106). 3. Remove the number 9 bearing from the reverse planetary carrier. Note that this planetary carrier has four pinion gears. 4. Remove the reverse planetary gear carrier (Fig. 106). 5. Remove the number 10 bearing from the input sun gear (Fig. 106). 6. Remove the input sun gear from the input carrier (Fig. 106). 7. Remove the number 11 bearing from the input carrier (Fig. 106). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 3454 Planetary Gears: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION PLANETARY GEARTRAIN / CLEANING Clean the planetary components in solvent and dry them with compressed air. INSPECTION Check sun gear and driving shell condition. Replace the gear if damaged or if the bushings are scored or worn. The bushings are not serviceable. Replace the driving shell if worn, cracked or damaged. Replace planetary gear sets if gears, pinion pins, or carrier are damaged in any way. Replace the annulus gears and supports if either component is worn or damaged. Replace the output shaft if the machined surfaces are scored, pitted, or damaged in any way. Also replace the shaft if the splines are damaged, or exhibits cracks at any location. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 3455 Planetary Gears: Service and Repair Assembly 45RFE - AUTOMATIC TRANSMISSION PLANETARY GEARTRAIN / ASSEMBLY 1. Clean and inspect all components. Replace any components, which show evidence of excessive wear or scoring. 2. Install the number 11 bearing into the input planetary carrier so that the inner race will be toward the front of the transmission (Fig. 106). 3. Install the input sun gear into the input carrier (Fig. 106). 4. Install the number 10 bearing onto the rear of the reverse planetary carrier with the inner race toward the carrier (Fig. 106). 5. Install the number 9 bearing onto the front of the reverse planetary carrier with the outer race toward the carrier and the inner race facing upward (Fig. 106). 6. Install the reverse planetary gear carrier into the input carrier (Fig. 106). 7. Install the input annulus gear into the input carrier (Fig. 106). 8. Install the snap-ring to hold the input annulus gear into the input carrier (Fig. 106). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation Solenoid Switch Valve / 45RFE - Automatic Transmission DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3483 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3484 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3485 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3486 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3487 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3491 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3492 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3493 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3494 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Adapter Housing Seal Seals and Gaskets: Service and Repair Adapter Housing Seal 45RFE - Automatic Transmission ADAPTER HOUSING SEAL / REMOVAL 1. Remove the transfer case from the transmission. 2. Using a screw mounted on a slide hammer, remove the adapter housing seal. INSTALLATION 1. Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the adapter housing using Seal Installer C-3860-A (Fig. 53). A properly installed seal is flush to the face of the seal bore. 3. Install the transfer case onto the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Adapter Housing Seal > Page 3499 Seals and Gaskets: Service and Repair Oil Pump Front Seal 45RFE - Automatic Transmission Oil Pump Front Seal / REMOVAL 1. Remove transmission from the vehicle. 2. Remove the torque converter from the transmission. 3. Using a screw mounted in a slide hammer, remove the oil pump front seal. INSTALLATION 1. Clean seal bore of the oil pump of any residue or particles from the original seal. 2. Install new oil seal in the oil pump housing using Seal Installer C-3860-A (Fig. 94). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3504 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3505 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3506 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3507 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3511 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3512 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3513 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3514 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3523 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3524 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3525 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3526 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3529 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3530 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3531 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3534 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3535 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3536 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3537 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3538 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3542 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3543 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3548 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3549 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3550 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3553 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3556 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments Shift Interlock Cable: Adjustments 45RFE - AUTOMATIC TRANSMISSION ADJUSTMENTS - BRAKE TRANSMISSION SHIFT INTERLOCK Correct cable adjustment is important to proper interlock operation. The gearshift cable must be correctly adjusted in order to shift out of PARK. ADJUSTMENT PROCEDURE 1. Remove the steering column trim as necessary for access to the brake transmission shift interlock. 2. Shift the transmission into the PARK position. 3. Pull upward on both the BTSI lock tab and the gearshift cable lock tab (Fig. 55). 4. Verify that the shift lever is in the PARK position. 5. Verify positive engagement of the transmission park lock by attempting to rotate the propeller shaft. The shaft will not rotate when the park lock is engaged. 6. Turn ignition switch to LOCK position. Be sure ignition key cylinder is in the LOCK position. Cable will not adjust correctly in any other position. 7. Ensure that the cable is free to self-adjust by pushing cable rearward and releasing. 8. Push the gearshift cable lock tab down until it snaps in place. 9. Locate the BTSI alignment hole in the bottom of the BTSI mechanism between the BTSI lock tab and the BTSI connector. 10. Move the BTSI assembly up or down on the gearshift cable until an appropriate size drill bit can be inserted into the alignment hole and through the assembly. 11. Push the BTSI lock tab down until it snaps into place and remove the drill bit. 12. Install any steering column trim previously removed. BTSI FUNCTION CHECK 1. Verify removal of ignition key allowed in PARK position only. 2. When the shift lever is in PARK, the ignition key cylinder should rotate freely from off to lock. When the shifter is in any other position, the ignition key should not rotate from off to lock. 3. Shifting out of PARK should be possible when the ignition key cylinder is in the off position. 4. Shifting out of PARK should not be possible while applying normal force, and ignition key cylinder is in the run or start positions, unless the foot brake pedal is depressed approximately 1/2 inch (12 mm). 5. Shifting out of PARK should not be possible when the ignition key cylinder is in the accessory or lock position. 6. Shifting between any gear and NEUTRAL, or PARK, may be done without depressing foot brake with ignition switch in run or start positions. 7. Engine starts must be possible with shifter lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any position other than PARK or NEUTRAL. 8. With shifter lever in the: - PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. - PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. - NEUTRAL position - Normal position. Engine starts must be possible. - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3570 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3571 Shift Solenoid: Description and Operation TRANSMISSION SOLENOID/ TRS ASSEMBLY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 116). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION - SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES 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 chart: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3572 L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3573 Shift Solenoid: Service and Repair Transmission Solenoid/TRS Assembly / 45RFE - Automatic Transmission REMOVAL 1. Remove the valve body from the transmission (Fig. 117). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 118). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Steering Column Shifter lever Screws ................................................................................................................................................... 12 Nm (105 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 3577 Shifter A/T: Description and Operation 45RFE - Automatic Transmission SHIFT MECHANISM / DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) OPERATION MANUAL LOW (1) Grange 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. GUpshifts into FOURTH will be delayed when the transmission fluid temperature is below 4.5°C (40°F) or above 115.5°C (240°F). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 3578 Shifter A/T: Service and Repair REMOVAL 1. Remove the knee blocker. 2. Loosen the steering column bolts enough to lower the column without removing. 3. Remove the upper and lower shrouds. 4. Disconnect over drive switch wiring. 5. Disconnect the shift cable from the pin and unsnap the cable adjusting clip. 6. Remove the screws retaining the gear shift lever. 7. Remove the blocker pin from the inhibit link slot. 8. Remove the gear shift lever from the steering column assembly. INSTALLATION 1. Install the lever assembly using care to install the pin in the blocker to inhibit slot and install the mounting screws and tighten to 12 Nm (105 in. lbs.). 2. Install the shift lever screws. Tighten the screws to 12 Nm (105 in. lbs.). 3. Connect the shift cable to the pin ensuring the shift lever is in PARK and snap the shift cable adjustment clip in place. 4. Connect over drive switch wiring. 5. Install the upper and lower shrouds. 6. Tighten the steering column mounting nuts to 28 Nm (250 in. lbs.). 7. Install the knee blocker. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection Shift Cable: Testing and Inspection 45RFE - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3583 Shift Cable: Adjustments 45RFE - Automatic Transmission GEARSHIFT CABLE / ADJUSTMENT Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (underneath the steering column) (Fig. 64) 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 downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3584 Shift Cable: Service and Repair 45RFE - Automatic Transmission GEARSHIFT CABLE / REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket (Fig. 58) or (Fig. 59). 4. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3585 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (Fig. 60). 6. Remove grommet from the dash panel. 7. Remove any steering column trim necessary to access the gearshift cable and BTSI mechanism. 8. Disconnect the BTSI wiring connector. 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle (Fig. 61). 10. Remove gearshift cable from vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3586 INSTALLATION 1. Route the transmission end of the gearshift cable through the opening in the dash panel (Fig. 62). 2. Seat the cable grommet into the dash panel opening. 3. Snap the cable into the steering column bracket so the retaining ears (Fig. 63) 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 downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism as necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3590 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Pressure Boost Valve <--> [Throttle Valve, A/T] > Component Information > Locations Pressure Boost Valve: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Pressure Boost Valve <--> [Throttle Valve, A/T] > Component Information > Locations > Page 3598 Pressure Boost Valve: Service and Repair Refer to Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body, A/T/Service and Repair/46RE Automatic Transmission/Disassembly for disassembly procedure. Refer to Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body, A/T/Service and Repair/46RE Automatic Transmission/Assembly for assembly procedure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Throttle Valve Cable/Linkage: Description and Operation 42RE (A-500) 4 Speed 42RE - Automatic Transmission TRANSMISSION THROTTLE VALVE CABLE DESCRIPTION Transmission throttle valve cable (Fig. 237) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3603 The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (Fig. 238). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3604 Throttle Valve Cable/Linkage: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TRANSMISSION THROTTLE VALVE CABLE DESCRIPTION Transmission throttle valve cable (Fig. 238) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3605 The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (Fig. 239). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed Throttle Valve Cable/Linkage: Adjustments 42RE (A-500) 4 Speed 42RE - Automatic Transmission ADJUSTMENTS - THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3608 3. Verify that lever on throttle body is at curb idle position (Fig. 239). Then verify that the transmission throttle lever (Fig. 240) is also at idle (fully forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction (Fig. 241). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3609 - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable Adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V. cable lock (A) into the UP position (Fig. 241). This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1 mm) (Fig. 241). 7. While holding the T.V. cable in the set position push the T.V. cable lock (A) into the down position (Fig. 241). This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3610 Throttle Valve Cable/Linkage: Adjustments 46RE (A-518) 4 Speed 46RE - Automatic Transmission ADJUSTMENTS - THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3611 3. Verify that lever on throttle body is at curb idle position (Fig. 240). Then verify that the transmission throttle lever (Fig. 241) is also at idle (fully forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction (Fig. 242). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3612 - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable Adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V. cable lock (A) into the UP position (Fig. 242). This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1 mm) (Fig. 242). 7. While holding the T.V. cable in the set position push the T.V. cable lock (A) into the down position (Fig. 242). This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed Torque Converter: Specifications Bolt, Torque Converter 270 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3617 Torque Converter: Specifications Bolt, Torque Convener 23 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3618 Torque Converter: Specifications Bolt, Torque Convener 270 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed Torque Converter: Description and Operation 42RE (A-500) 4 Speed 42RE - Automatic Transmission TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 242) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the all transmission fluid cooler(s) and lines. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3621 IMPELLER The impeller (Fig. 243) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3622 TURBINE The turbine (Fig. 244) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3623 STATOR The stator assembly (Fig. 245) is mounted on a stationary shaft, which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 246). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3624 Torque Converter: Description and Operation 45RFE 4 Speed/545RFE 5 Speed 45RFE - Automatic Transmission TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 107) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump and contains an O-ring seal to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the fluid cooler and lines. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3625 IMPELLER The impeller (Fig. 108) 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3626 TURBINE The turbine (Fig. 109) 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3627 STATOR The stator assembly (Fig. 110) is mounted on a stationary shaft, which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 111). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3628 Torque Converter: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 243) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the all transmission fluid cooler(s) and lines. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3629 IMPELLER The impeller (Fig. 244) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3630 TURBINE The turbine (Fig. 245) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3631 STATOR The stator assembly (Fig. 246) is mounted on a stationary shaft, which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 247). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed Torque Converter: Service and Repair 42RE (A-500) 4 Speed 42RE - Automatic Transmission TORQUE CONVERTER REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 250). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3634 Torque Converter: Service and Repair 45RFE 4 Speed/545RFE 5 Speed 45RFE - Automatic Transmission TORQUE CONVERTER REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper or crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub O-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 115). Surface of converter lugs should be at least 13 mm (1/2 inch) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3635 Torque Converter: Service and Repair 46RE (A-518) 4 Speed 46RE - Automatic Transmission TORQUE CONVERTER REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 251). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > 42RE (A-500) 4 Speed Torque Converter Check Valve: Description and Operation 42RE (A-500) 4 Speed 42RE - Automatic Transmission DESCRIPTION The drainback valve is located in the transmission cooler outlet (pressure) line. OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have a hose nipple at one end, while the opposite end is threaded for a flare fitting. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3640 Torque Converter Check Valve: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission DESCRIPTION The drainback valve is located in the transmission cooler outlet (pressure) line. OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have a hose nipple at one end, while the opposite end is threaded for a flare fitting. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Page 3641 Torque Converter Check Valve: Service and Repair TORQUE CONVERTER DRAINBACK VALVE The converter drainback check valve is located in the cooler outlet (pressure) line near the radiator tank. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be replaced. The valve must be removed whenever the cooler and lines are reverse flushed. The valve can be flow tested when necessary. The procedure is exactly the same as for flow testing a cooler. If the valve is restricted, installed backwards, or in the wrong line, it will cause an overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an overheating condition and eventual transmission failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Torque Converter Clutch: Description and Operation 42RE (A-500) 4 Speed 42RE - Automatic Transmission TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 247) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3646 OPERATION The converter impeller (Fig. 248) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member) which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 249). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3647 Torque Converter Clutch: Description and Operation 45RFE 4 Speed/545RFE 5 Speed 45RFE - Automatic Transmission TORQUE CONVERTER CLUTCH (TCC) DESCRIPTION The TCC (Fig. 112) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston with friction material was added to the turbine assembly to provide this mechanical lock-up. In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3648 OPERATION The converter impeller (Fig. 113) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 114). 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3649 over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, and fourth gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear. If the control switch is in the OFF position, the clutch will engage after the shift to third gear. The TCM controls the torque converter by way of internal logic software. The programming of the software provides the TCM with control over the L/R-CC Solenoid. There are four output logic states that can be applied as follows: - No EMCC - Partial EMCC - Full EMCC - Gradual-to-no EMCC NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL-TO-NO EMCC This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at midthrottle by decreasing the L/R Solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3650 Torque Converter Clutch: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TORQUE CONVERTER CLUTCH (TCC) DESCRIPTION The TCC (Fig. 248) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3651 OPERATION The converter impeller (Fig. 249) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 250). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3652 "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover. Starting with the two rear cover-to-engine bolts, tighten bolts 1 (Fig. 87) to 54 Nm (40 ft. lbs.), then tighten bolts 2 (Fig. 87) and 3 to 54 Nm (40 ft. lbs.) in the sequence shown. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications > Page 3659 Torque Converter Cover: Description and Operation DESCRIPTION The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine bedplate. OPERATION The structural cover provides additional powertrain stiffness and reduces noise and vibration. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications > Page 3660 Torque Converter Cover: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove the left hand exhaust pipe from exhaust manifold. 3. Loosen the right hand exhaust manifold-to-exhaust pipe retaining bolts. 4. Remove the eight bolts retaining structural cover (Fig. 86) in the sequence shown. 5. Pivot the exhaust pipe downward and remove the structural cover. INSTALLATION CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover. 1. Position the structural cover in the vehicle. 2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover. 4. Starting with the two rear cover-to-engine bolts, tighten bolts 1 (Fig. 87) to 54 Nm (40 ft. lbs.), then tighten bolts 2 (Fig. 87) and 3 to 54 Nm (40 ft. lbs.) in the sequence shown. 5. Install the exhaust pipe on left hand exhaust manifold. 6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 Nm (15 - 20 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3664 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3665 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3666 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3667 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Transmission-Auxiliary Oil Cooler Bolts 90 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3671 Transmission Cooler: Description and Operation TRANSMISSION COOLER DESCRIPTION CAUTION: On in-radiator type oil coolers, if transmission oil cooler is leaking, engine coolant may enter cooler, or transmission oil may enter engine cooling system. Both engine cooling system and transmission oil circuit should be drained, flushed, and inspected. There are two types of transmission oil coolers used. One type of cooler is the in-radiator type or oil to coolant type (Fig. 1). This type oil cooler is not serviceable. The second type used is a remote type auxiliary oil cooler or oil to air cooler (Fig. 2). The oil to air type cooler is located in front of the radiator, and is serviceable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3672 Transmission Cooler: Service and Repair FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906-B Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906-B. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906-B. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar ATE +4, type 9602, Automatic Transmission Fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3678 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3679 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3680 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3681 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3684 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3685 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 3686 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3689 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3690 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3691 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3692 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3693 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Bolt, Clevis Bracket To Crossmember 35 ft.lb Bolt, Clevis Bracket To Rear Support 50 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3700 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3701 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > Page 3705 Transmission Pressure Test Port: Description and Operation 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3710 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3711 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3712 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3715 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3718 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Valve Body: Specifications Bolt, Valve Body To Case 100 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3726 Valve Body: Specifications Bolt, Valve Body To Case 105 in.lb Screw, Valve Body To Transfer Plate 50 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3727 Valve Body: Specifications Bolt, Valve Body To Case 100 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3728 Valve Body: Locations 45RFE - Automatic Transmission 45RFE - Automatic Transmission Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3729 Valve Body: Description and Operation 45RFE - Automatic Transmission DESCRIPTION 45RFE - Automatic Transmission 45RFE - Automatic Transmission The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components (Fig. 119) and (Fig. 120): - Solenoid switch valve - Manual valve - Low/reverse switch valve Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3730 - 5 Accumulators - 7 check balls 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 2nd, 3rd, and 4th gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver, with a lever located on the top of the valve body. The valve is connected mechanically by a cable to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (Fig. 121) that engages the "roostercomb" of the TRS selector plate. LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation Removal 45RFE - AUTOMATIC TRANSMISSION REMOVAL The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter from valve body. (Fig. 122) 7. Remove bolts attaching valve body to transmission case (Fig. 123). 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3733 Installation 45RFE - AUTOMATIC TRANSMISSION INSTALLATION 1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn. 2. Place TRS selector plate in the PARK position. 3. Place the transmission in the PARK position. 4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly. 5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever. 6. Seat valve body in case and install one or two bolts to hold valve body in place. 7. Tighten valve body bolts alternately and evenly to 12 Nm (105 inch lbs.) torque. 8. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 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. 9. Place replacement filter in position on valve body and into the oil pump. 10. Install screw to hold filter to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 11. Connect the solenoid and pressure switch assembly connector. 12. Install oil pan. Tighten pan bolts to 12 Nm (105 inch lbs.) torque. 13. Lower vehicle and fill transmission with Mopar ATF +4, type 9602, fluid. 14. Check and adjust gearshift cable, if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3734 Valve Body: Service and Repair Disassemble & Assemble Disassembly 45RFE - AUTOMATIC TRANSMISSION DISASSEMBLY 1. Remove the screws holding the solenoid and pressure switch assembly to the valve body (Fig. 124). Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (Fig. 125) onto the valve body. 4. Remove the detent spring from the valve body. 5. Remove the TRS selector plate from the valve body and the manual valve. 6. Remove the clutch passage seals from the valve body, if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3735 7. Remove the screws holding the accumulator cover onto the valve body (Fig. 126). 8. Remove the accumulator springs and pistons from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls (Fig. 127). 12. Remove the check balls from the valve body. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3736 13. Remove the retainers securing the solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. (Fig. 128) Assembly 45RFE - AUTOMATIC TRANSMISSION ASSEMBLY 1. Lubricate valves, springs, and the housing valve bores with clean transmission fluid. 2. Install solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body. 3. Install the retainers to hold each valve into the valve body. 4. Install the valve body check balls into their proper locations. 5. Position the transfer plate onto the valve body. 6. Install the screws to hold the transfer plate to the valve body. Tighten the screws to 5.6 Nm (50 inch lbs.). 7. Install the accumulator pistons and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston has only one spring. 8. Position the accumulator cover onto the valve body. 9. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 4.5 Nm (40 inch lbs.). 10. Install the TRS selector plate onto the valve body and the manual valve. 11. Install the solenoid and pressure switch assembly onto the valve body. 12. Install the screws to hold the solenoid and pressure switch assembly onto the valve body. Tighten the screws to 5.7 Nm (50 inch lbs.). Tighten the screws adjacent to the arrows cast into the bottom of the transfer plate first. 13. Position the detent spring onto the valve body. 14. Install the screw to hold the detent spring onto the valve body. Tighten the screw to 4.5 Nm (40 inch lbs.). 15. Install new clutch passage seals onto the valve body, if necessary Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3737 Valve Body: Service and Repair Cleaning and Inspection 45RFE - AUTOMATIC TRANSMISSION CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. (Fig. 129) Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3738 Inspect the valves and plugs (Fig. 130) for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3739 Inspect all the fluid seals on the valve body (Fig. 131). 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation Clutch Disc: Description and Operation DESCRIPTION The clutch disc friction material is riveted to the disc hub (Fig. 4). The hub bore is splined for installation on the transmission input shaft. The clutch disc has cushion springs in the disc hub to dampen disc vibrations during application and release of the clutch. OPERATION The clutch disc is held onto the surface of the flywheel by the force exerted by the pressure plate's diaphragm spring. The friction material of the clutch disc then transfers the engine torque from the fly-wheel and pressure plate to the input shaft of the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3744 Clutch Disc: Service and Repair CLUTCH DISC / REMOVAL 1. Raise vehicle. 2. Remove transmission and clutch housing as assembly. 3. If pressure plate is being removed for access to another component, mark position of pressure plate cover on flywheel with small punch marks (Fig. 4). 4. Loosen pressure plate cover bolts evenly and in rotation to relieve spring tension. Loosen bolts a few threads at a time to avoid warping cover. 5. Remove cover bolts, pressure plate and clutch disc. INSTALLATION NOTE: Clean flywheel surface with solvent. Scuff sand surface with 120/180 grit emery cloth to remove minor scratches and glazing. 1. Check new clutch disc for runout and free operation on input shaft splines. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Position clutch disc on the flywheel. 4. Insert alignment tool or spare input shaft through clutch disc and into pilot bearing (Fig. 5). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3745 5. Verify that disc hub is positioned correctly. The raised portion of the hub faces away from the flywheel (Fig. 6). 6. Position pressure plate cover over disc and on flywheel. 7. Install cover bolts finger tight. 8. Tighten cover bolts evenly (and in rotation) a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. 9. Tighten cover bolts to: - 2.5L bolts to.........28 Nm (21 ft. lbs.). - 5/16 inch bolts to.........23 Nm (17 ft. lbs.). - 3/8 inch bolts to.............41 Nm (30 ft. lbs.). 10. Apply light coat of Mopar high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of front bearing retainer. CAUTION: Do not over lubricate shaft splines. This could result in grease contamination of disc. 11. Install transmission as assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Clutch Fluid Reservoir Clutch fluid level is checked at the master cylinder reservoir. An indicator ring is provided on the outside of the reservoir. With the cap and diaphragm removed, fluid level should not be above indicator ring. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 3751 Clutch Fluid: Fluid Type Specifications Information not supplied by the manufacturer. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Page 3752 Clutch Fluid: Testing and Inspection MASTER CYLINDER - INSPECTION The clutch fluid reservoir, master cylinder, slave cylinder and fluid lines are pre-filled with fluid at the factory during assembly operations. The hydraulic system should not require additional fluid under normal circumstances. The reservoir fluid level will actually increase as normal clutch wear occurs. Avoid overfilling or removing fluid from the reservoir. Clutch fluid level is checked at the master cylinder reservoir. An indicator ring is provided on the outside of the reservoir. With the cap and diaphragm removed, fluid level should not be above indicator ring. To avoid contaminating the hydraulic fluid during inspection, wipe reservoir and cover clean before removing the cap. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Description and Operation Clutch Linkage: Description and Operation DESCRIPTION The hydraulic linkage consists of a clutch master cylinder, reservoir, a clutch slave cylinder and an interconnecting fluid line (Fig. 14). The clutch master cylinder push rod is connected to the clutch pedal. The slave cylinder push rod is connected to the clutch release fork. The master cylinder is mounted on the driver side of the dash panel adjacent to the brake master cylinder and booster assembly. The factory installed hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should not be disconnected or tampered with. The hydraulic linkage is serviced as an assembly only. The individual components that form the linkage assembly can-not be overhauled or serviced separately. OPERATION The clutch linkage uses hydraulic pressure to operate the clutch. Depressing the clutch pedal develops fluid pressure in the clutch master cylinder. This pressure is transmitted to the slave cylinder through a connecting line. In turn, the slave cylinder operates the clutch release lever. The slave cylinder has an integral spring which preloads the release bearing against the clutch diaphragm fingers to maintain zero free-play. Slave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward relieving clamp force on the disc. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Description and Operation > Page 3756 Clutch Linkage: Service and Repair LINKAGE / REMOVAL NOTE: The hydraulic linkage is serviced as a complete assembly only. The individual components must not be overhauled or serviced separately. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". 1. Raise and support vehicle. 2. Remove nuts attaching slave cylinder to clutch housing (Fig. 10). CAUTION: Do not disconnect slave cylinder quick disconnect. If disconnected hydraulic linkage must be replaced. 3. Remove slave cylinder from housing. 4. Remove hydraulic fluid line clip from the lower dash panel flange. 5. Lower vehicle. 6. Remove clip holding clutch master cylinder push rod to clutch pedal (Fig. 10). 7. Slide clutch master cylinder push rod off clutch pedal pin. 8. Disconnect clutch pedal position switch connector from wiring harness. 9. Remove nuts holding clutch master cylinder to dash panel. 10. Verify that cap on clutch master cylinder reservoir is tight to avoid undue spillage during removal. 11. Remove screws attaching clutch fluid reservoir to dash panel. 12. Pull clutch master cylinder from dash panel. 13. Remove hydraulic linkage components from vehicle as an assembly. INSTALLATION NOTE: The hydraulic linkage is serviced as a complete assembly only. The individual components must not be serviced separately. 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines and reservoir in vehicle. 3. Insert clutch master cylinder in dash panel. 4. Position reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Description and Operation > Page 3757 5. Install nuts that hold clutch master cylinder to dash panel. Tighten nuts to 54 Nm (40 ft. lbs.). 6. Apply light coating of grease to the inner diameter of the master cylinder push-rod and the outer diameter of the clutch pedal pin. 7. Install clutch master cylinder push rod on clutch pedal pin. Secure rod with retaining clip. 8. Connect clutch pedal position switch connector from wiring harness. 9. Raise vehicle. 10. Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure end of rod is securely engaged in release lever. Check this before installing cylinder attaching nuts. NOTE: If new clutch linkage is being installed, do not remove plastic shipping strap from the slave cylinder push rod. The strap will break on its own upon first clutch application. 11. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.). 12. Install hydraulic fluid line clip into the hole in the lower dash panel flange. 13. Verify that fluid line from master cylinder to slave cylinder is properly routed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair CLUTCH PEDAL / REMOVAL 1. Remove retaining clip securing push rod on clutch pedal (Fig. 11). 2. Slide push rod off clutch pedal pin. 3. Remove snap ring and washer attaching clutch pedal to the pivot shaft. 4. Slide pedal off pivot shaft and remove pedal. 5. Remove and inspect bushings in pedal bore. Replace bushings if worn or cracked. INSTALLATION 1. Lubricate pedal bushings and shaft with a silicone grease or with Mopar multi-mileage grease. 2. Install bushings in pedal bore and on pin. 3. Install pedal on pivot shaft. 4. Secure pedal on shaft with washer and snap ring. 5. Apply light coating of grease to the inner diameter of the master cylinder push-rod and the outer diameter of the clutch pedal pin. 6. Connect push rod to pedal and secure rod with retaining clip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Clutch Switch: Diagrams Clutch Interlock Switch Jumper (A/T) Clutch Interlock Switch (M/T) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Page 3764 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position switch is in the starter circuit. The switch is located on the clutch master cylinder push rod. OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Page 3765 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION SWITCH REMOVAL AND INSTALLATION Switch is not serviced separately. If switch replacement is necessary, replace clutch master cylinder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation Clutch Release Bearing: Description and Operation DESCRIPTION A conventional release bearing (Fig. 9) is used to engage and disengage the clutch pressure plate assembly. The clutch release bearing is mounted on the transmission front bearing retainer. The bearing is attached to the release fork, which moves the bearing into contact with the clutch cover diaphragm spring. OPERATION The release bearing is operated by a release fork in the clutch housing. Slave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward relieving clamp force on the disc. Releasing pedal pressure removes clutch hydraulic pressure. The release bearing then moves away from the diaphragm spring which allows the pressure plate to exert clamping force on the clutch disc. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation > Page 3769 Clutch Release Bearing: Service and Repair CLUTCH RELEASE BEARING / REMOVAL 1. Remove transmission. 2. Disconnect release bearing from fork and remove bearing (Fig. 8). INSTALLATION 1. Inspect release bearing slide surface of transmission front bearing retainer. Replace retainer if slide surface is scored, worn or cracked. 2. Inspect release fork and fork pivot (Fig. 8). Be sure pivot is secure and in good condition. Be sure fork is not distorted or worn. Replace release fork retainer spring if bent or damaged in any way. 3. Lightly lubricate pilot bearing, input shaft splines, bearing retainer slide surface, fork pivot and release fork pivot surface with Mopar high temperature bearing grease. 4. Install release fork and bearing. Verify fork and bearings are properly secured. 5. Install transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Description and Operation Pilot Bearing: Description and Operation DESCRIPTION Vehicles equipped with a manual transmission utilize a pilot bearing. This bearing is located in the back of the engine crankshaft. Depending on the type of engine or application, the pilot bearing can be a solid soft metallic bushing or a fully caged needle bearing. The pilot bearing's main functions are to support the transmission input shaft, maintain proper alignment of the clutch assembly and allow the transmission main shaft to rotate at a different speed than the engine mounted crankshaft. OPERATION The pilot bearing supports the transmission input shaft, maintains proper clutch assembly alignment and allows the transmission input shaft to rotate at a different speed (RPM) than the engine mounted crankshaft. When the clutch pedal is depressed (with vehicle in drive mode) the clutch disc slows and stops therefore, the transmission input shaft slows and stops as well. The pilot bearing allows the engine crankshaft to continue to rotate even though the transmission input shaft is stationary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Description and Operation > Page 3773 Pilot Bearing: Service and Repair PILOT BEARING / REMOVAL 1. Remove transmission, transfer case, if equipped, and clutch housing. 2. Remove clutch cover and disc. 3. Using a suitable blind hole puller, remove pilot bearing. INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing with clutch alignment tool (Fig. 9). Keep bearing straight during installation. Do not allow bearing to become cocked. Tap bearing into place until flush with edge of bearing bore. Do not recess bearing. 3. Install clutch cover and disc. 4. Install clutch housing, transmission and transfer case, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Cover Bolts 2.5 L ..................................................................................................................................................... .................................................. 28 Nm (21 Ft Lbs) 5/16 ..................................................................... ................................................................................................................................... 23 Nm (17 Ft Lbs) 3/8 ................................................................................................................................................ .......................................................... 41 Nm (30 Ft Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3777 Pressure Plate: Description and Operation DESCRIPTION The clutch pressure plate assembly is a diaphragm type with a one-piece spring and multiple release fingers (Fig. 11). The pressure plate release fingers are preset during manufacture and are not adjustable. The assembly also contains the cover, pressure plate, and fulcrum components. OPERATION The clutch pressure plate assembly clamps the clutch disc against the flywheel. When the release bearing is depressed by the shift fork, the pressure exerted on the clutch disc by the pressure plate spring is decreased. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward relieving clamp force on the disc. The clutch disc is disengaged and freewheeling at this point. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Assembly Fluid Front Axle - C205F .............................................................................................................................. .................................................. 1.66 Liters (3.5 pts.) Rear Axle - 9 1/4 Inch .......................................................................................................................... ................................................. 2.32 Liters (4.9 pts.) With Trac-Lok add 148 ml (5 oz) of friction modifier. Rear Axle - 8 1/4 Inch .......................................................................................................................... ................................................. 2.22 Liters (4.7 pts.) With Trac-Lok add 148 ml (5 oz) of friction modifier. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3786 Fluid - Differential: Fluid Type Specifications Front Axle - C205F The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. Rear Axle - 9 1/4 Inch The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. Rear Axle - 8 1/4 Inch The Lubricant should have MIL-L-2105C and API GL 5 quality specifictions. Lubricant is a thermally stable SAE 75W-90 Gear Lubricant. NOTE:Trac-lok equipped axles require a friction modifier be added to the lubricant. CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3787 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F Pinion Gear: Service and Repair Front Axle - C205F C205F Front Axle - Pinion Gear/Ring Gear/Tone Ring REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. 1. Remove differential from axle housing. 2. Place differential case in a vise with soft jaw (Fig. 34). 3. Remove bolts holding ring gear to differential case. 4. Drive ring gear from differential case with a soft hammer (Fig. 34). 5. Mark the companion yoke and companion flange for installation reference. 6. Remove companion flange bolts and tie the propeller shaft to the vehicle underbody. 7. Rotate companion flange three or four times and verify flange rotates smoothly. 8. Record pinion rotating torque an inch pound torque wrench for installation reference (Fig. 35). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3792 9. Install bolts into two of the threaded holes in the companion flange 180° apart. 10. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so that the Holder 6719 is held to the flange. 11. Remove the pinion nut. 12. Remove the companion flange with Remover C-452 (Fig. 36). 13. Remove pinion from differential housing (Fig. 37). 14. Remove pinion seal with a pry tool or a slide hammer mounted screw. 15. Remove oil slinger, if equipped, and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3793 16. Remove front pinion bearing cup with Remover D-103 and Handle C-4171 (Fig. 38). 17. Remove rear pinion bearing cup from housing (Fig. 39) with Remover 8401 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3794 18. Remove collapsible preload spacer (Fig. 40). 19. Remove rear pinion bearing with Puller/Press C-293-PA and Adapters C-293-42 (Fig. 41). 20. Remove depth shims from the pinion shaft and record thickness of shims. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. If ring and pinion gears or bearings are replaced, refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the bearing cups. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3795 2. Install rear pinion bearing cup with Installer D-145 and Driver Handle C-4171 (Fig. 42) and verify cup is seated. 3. Install front pinion bearing cup with Installer D-129 and Handle C-4171 (Fig. 43) and verify cup is seated. 4. Install pinion front bearing and oil slinger if equipped. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3796 6. Install pinion seal with Installer C-3972-A and Handle C-4171 (Fig. 44). 7. Place the proper thickness depth shim (Fig. 45) on the pinion shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3797 8. Install rear bearing and slinger if equipped, onto the pinion shaft with Installer 6448 (Fig. 46) and a press. 9. Install new collapsible preload spacer onto the pinion shaft (Fig. 47). 10. Install the pinion gear in the housing. 11. Install the companion flange with Installer C-3718 and Holder 6719. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3798 12. Install new pinion nut and tighten to 271 Nm (200 ft. lbs.) (Fig. 48). 13. Using Holder 6719 and a torque wrench set at 474 Nm (350 ft. lbs.). Tighten pinion nut until bearing end play is taken up. 14. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until desired rotating torque is achieved. Measure the rotating torque frequently to avoid overcrushing the collapsible spacer (Fig. 49). The pinion rotating torque should be: Original Bearings:...........1 to 2.5 Nm (10 to 20 inch lbs.) - New Bearings:.............1.7 to 2.5 Nm (15 to 22 inch lbs.) CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. 15. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 16. Invert the differential case in the vise. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3799 17. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.) (Fig. 50). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. 18. Install differential in axle housing and verify gear mesh and contact pattern. 19. Install differential cover and fill with gear lubricant. 20. Install propeller shaft with reference marks aligned. 21. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3800 Pinion Gear: Service and Repair Rear Axle - 8 1/4 8 1/4 Inch REAR AXLE - PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. 1. Remove differential from the axle housing. 2. Mark the companion flange and propeller shaft for installation alignment. 3. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 4. Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 47). 5. Remove ring gear bolts from the differential case. 6. Drive ring gear off the differential case with a rawhide hammer (Fig. 47). 7. Install bolts into two of the threaded holes in the companion flange 180° apart. 8. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 9. Hold companion flange with Holder 6719 and remove companion flange nut and washer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3801 10. Remove the companion flange with Remover C-452 (Fig. 48). 11. Remove pinion from housing (Fig. 49). 12. Remove pinion seal with a pry tool or slide hammer mounted screw. 13. Remove oil slinger if equipped and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3802 14. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 50). 15. Remove rear bearing cup from housing (Fig. 51) with Remover C-4307 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3803 16. Remove collapsible preload spacer (Fig. 52). 17. Remove rear bearing from pinion (Fig. 53) with Puller/Press C-293-PA and Adapters C-293-47. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3804 18. Remove pinion depth shim (Fig. 54) from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or equivalent stick lubricant to outside surface of pinion bearing cups. 2. Install rear pinion bearing cup (Fig. 55) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3805 3. Install front pinion bearing cup (Fig. 56) with Installer D-130 and Handle C-4171 and verify cup is seated. 4. Lubricate and install front pinion bearing and oil slinger if equipped. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 57). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3806 6. Install pinion depth shim (Fig. 58) on the pinion shaft. 7. Install rear pinion bearing and slinger if equipped, on the pinion (Fig. 59) with Installer 6448 and a press. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3807 8. Install a new collapsible spacer on the pinion gear shaft (Fig. 60). 9. Lubricate rear pinion bearing and install pinion into the housing. 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. With a torque wrench tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 61). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3808 15. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 62). 16. Check pinion rotating torque with an inch pound torque wrench (Fig. 62). The pinion rotating torque should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. 18. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 19. Invert the differential case in the vise. 20. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.) (Fig. 63). CAUTION: Never reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3809 21. Install differential in housing and verify gear mesh, backlash and contact pattern. 22. Install differential cover and fill with gear lubricant. 23. Install propeller shaft with reference marks aligned. 24. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3810 Pinion Gear: Service and Repair Rear Axle - 9 1/4 9 1/4 Inch REAR AXLE - PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Raise and support vehicle. 2. Remove wheel and tire assemblies. 3. Mark companion flange and propeller shaft for installation reference. 4. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 5. Remove axle shafts. 6. Remove differential from the differential housing. 7. Place differential case in a vise with soft metal jaw protectors. 8. Remove ring gear bolts from the differential case. 9. Drive ring gear off the differential case with a rawhide hammer (Fig. 53). 10. Install bolts into two of the threaded holes in the companion flange 180° apart. 11. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 12. Use Holder 6719 to hold companion flange and remove the companion flange nut and washer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3811 13. Remove the companion flange from the pinion with Remover C-452 (Fig. 54). 14. Remove the pinion from housing (Fig. 55). 15. Remove pinion seal with a pry tool or slide hammer mounted screw. 16. Remove oil slinger if equipped and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3812 17. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 56). 18. Remove the rear bearing cup from housing (Fig. 57) with Remover C-4307 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3813 19. Remove the collapsible preload spacer (Fig. 58). 20. Remove rear bearing from the pinion (Fig. 59) with Puller/Press C-293-PA and Adapters C-293-47. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3814 21. Remove pinion depth shims (Fig. 60) from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not one gear without replacing the matching gear. If ring and pinion gears, or bearings are replaced, refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or stick lubricant to outside surface of pinion bearing cups. 2. Install rear pinion bearing cup (Fig. 61) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3815 3. Install front pinion bearing cup (Fig. 62) with Installer D-129 and Handle C-4171 and verify cup is seated. 4. Install lubricate and install front pinion bearing into the housing. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 63). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3816 6. Install pinion depth shim (Fig. 64) on the pinion shaft. 7. Install rear bearing on the pinion (Fig. 65) with Installer 6448 and a press. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3817 8. Install a new collapsible spacer on the pinion shaft (Fig. 66). 9. Lubricate rear pinion bearing and install the pinion into the housing. 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. With a torque wrench tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 67). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3818 15. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 68). 16. Check pinion rotating torque with an inch pound torque wrench (Fig. 68). The pinion rotating torque should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. 18. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 19. Invert the differential case in the vise. 20. Install new ring gear bolts and alternately tighten to 156 Nm (115 ft. lbs.) (Fig. 69). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. 21. Install differential in housing and verify gear mesh, backlash and contact pattern. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3819 22. Install axle shafts. 23. Install wheel and tire assemblies. 24. Install differential cover and fill with gear lubricant. 25. Install propeller shaft with reference marks aligned. 26. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F Ring Gear: Service and Repair Front Axle - C205F C205F Front Axle - Pinion Gear/Ring Gear/Tone Ring REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. 1. Remove differential from axle housing. 2. Place differential case in a vise with soft jaw (Fig. 34). 3. Remove bolts holding ring gear to differential case. 4. Drive ring gear from differential case with a soft hammer (Fig. 34). 5. Mark the companion yoke and companion flange for installation reference. 6. Remove companion flange bolts and tie the propeller shaft to the vehicle underbody. 7. Rotate companion flange three or four times and verify flange rotates smoothly. 8. Record pinion rotating torque an inch pound torque wrench for installation reference (Fig. 35). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3824 9. Install bolts into two of the threaded holes in the companion flange 180° apart. 10. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so that the Holder 6719 is held to the flange. 11. Remove the pinion nut. 12. Remove the companion flange with Remover C-452 (Fig. 36). 13. Remove pinion from differential housing (Fig. 37). 14. Remove pinion seal with a pry tool or a slide hammer mounted screw. 15. Remove oil slinger, if equipped, and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3825 16. Remove front pinion bearing cup with Remover D-103 and Handle C-4171 (Fig. 38). 17. Remove rear pinion bearing cup from housing (Fig. 39) with Remover 8401 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3826 18. Remove collapsible preload spacer (Fig. 40). 19. Remove rear pinion bearing with Puller/Press C-293-PA and Adapters C-293-42 (Fig. 41). 20. Remove depth shims from the pinion shaft and record thickness of shims. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. If ring and pinion gears or bearings are replaced, refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the bearing cups. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3827 2. Install rear pinion bearing cup with Installer D-145 and Driver Handle C-4171 (Fig. 42) and verify cup is seated. 3. Install front pinion bearing cup with Installer D-129 and Handle C-4171 (Fig. 43) and verify cup is seated. 4. Install pinion front bearing and oil slinger if equipped. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3828 6. Install pinion seal with Installer C-3972-A and Handle C-4171 (Fig. 44). 7. Place the proper thickness depth shim (Fig. 45) on the pinion shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3829 8. Install rear bearing and slinger if equipped, onto the pinion shaft with Installer 6448 (Fig. 46) and a press. 9. Install new collapsible preload spacer onto the pinion shaft (Fig. 47). 10. Install the pinion gear in the housing. 11. Install the companion flange with Installer C-3718 and Holder 6719. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3830 12. Install new pinion nut and tighten to 271 Nm (200 ft. lbs.) (Fig. 48). 13. Using Holder 6719 and a torque wrench set at 474 Nm (350 ft. lbs.). Tighten pinion nut until bearing end play is taken up. 14. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until desired rotating torque is achieved. Measure the rotating torque frequently to avoid overcrushing the collapsible spacer (Fig. 49). The pinion rotating torque should be: Original Bearings:...........1 to 2.5 Nm (10 to 20 inch lbs.) - New Bearings:.............1.7 to 2.5 Nm (15 to 22 inch lbs.) CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. 15. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 16. Invert the differential case in the vise. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3831 17. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.) (Fig. 50). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. 18. Install differential in axle housing and verify gear mesh and contact pattern. 19. Install differential cover and fill with gear lubricant. 20. Install propeller shaft with reference marks aligned. 21. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3832 Ring Gear: Service and Repair Rear Axle - 8 1/4 8 1/4 Inch REAR AXLE - PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. 1. Remove differential from the axle housing. 2. Mark the companion flange and propeller shaft for installation alignment. 3. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 4. Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 47). 5. Remove ring gear bolts from the differential case. 6. Drive ring gear off the differential case with a rawhide hammer (Fig. 47). 7. Install bolts into two of the threaded holes in the companion flange 180° apart. 8. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 9. Hold companion flange with Holder 6719 and remove companion flange nut and washer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3833 10. Remove the companion flange with Remover C-452 (Fig. 48). 11. Remove pinion from housing (Fig. 49). 12. Remove pinion seal with a pry tool or slide hammer mounted screw. 13. Remove oil slinger if equipped and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3834 14. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 50). 15. Remove rear bearing cup from housing (Fig. 51) with Remover C-4307 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3835 16. Remove collapsible preload spacer (Fig. 52). 17. Remove rear bearing from pinion (Fig. 53) with Puller/Press C-293-PA and Adapters C-293-47. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3836 18. Remove pinion depth shim (Fig. 54) from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or equivalent stick lubricant to outside surface of pinion bearing cups. 2. Install rear pinion bearing cup (Fig. 55) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3837 3. Install front pinion bearing cup (Fig. 56) with Installer D-130 and Handle C-4171 and verify cup is seated. 4. Lubricate and install front pinion bearing and oil slinger if equipped. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 57). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3838 6. Install pinion depth shim (Fig. 58) on the pinion shaft. 7. Install rear pinion bearing and slinger if equipped, on the pinion (Fig. 59) with Installer 6448 and a press. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3839 8. Install a new collapsible spacer on the pinion gear shaft (Fig. 60). 9. Lubricate rear pinion bearing and install pinion into the housing. 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. With a torque wrench tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 61). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3840 15. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 62). 16. Check pinion rotating torque with an inch pound torque wrench (Fig. 62). The pinion rotating torque should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. 18. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 19. Invert the differential case in the vise. 20. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.) (Fig. 63). CAUTION: Never reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3841 21. Install differential in housing and verify gear mesh, backlash and contact pattern. 22. Install differential cover and fill with gear lubricant. 23. Install propeller shaft with reference marks aligned. 24. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3842 Ring Gear: Service and Repair Rear Axle - 9 1/4 9 1/4 Inch REAR AXLE - PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Raise and support vehicle. 2. Remove wheel and tire assemblies. 3. Mark companion flange and propeller shaft for installation reference. 4. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 5. Remove axle shafts. 6. Remove differential from the differential housing. 7. Place differential case in a vise with soft metal jaw protectors. 8. Remove ring gear bolts from the differential case. 9. Drive ring gear off the differential case with a rawhide hammer (Fig. 53). 10. Install bolts into two of the threaded holes in the companion flange 180° apart. 11. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 12. Use Holder 6719 to hold companion flange and remove the companion flange nut and washer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3843 13. Remove the companion flange from the pinion with Remover C-452 (Fig. 54). 14. Remove the pinion from housing (Fig. 55). 15. Remove pinion seal with a pry tool or slide hammer mounted screw. 16. Remove oil slinger if equipped and front pinion bearing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3844 17. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 56). 18. Remove the rear bearing cup from housing (Fig. 57) with Remover C-4307 and Handle C-4171. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3845 19. Remove the collapsible preload spacer (Fig. 58). 20. Remove rear bearing from the pinion (Fig. 59) with Puller/Press C-293-PA and Adapters C-293-47. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3846 21. Remove pinion depth shims (Fig. 60) from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not one gear without replacing the matching gear. If ring and pinion gears, or bearings are replaced, refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar Door Ease or stick lubricant to outside surface of pinion bearing cups. 2. Install rear pinion bearing cup (Fig. 61) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3847 3. Install front pinion bearing cup (Fig. 62) with Installer D-129 and Handle C-4171 and verify cup is seated. 4. Install lubricate and install front pinion bearing into the housing. 5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 63). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3848 6. Install pinion depth shim (Fig. 64) on the pinion shaft. 7. Install rear bearing on the pinion (Fig. 65) with Installer 6448 and a press. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3849 8. Install a new collapsible spacer on the pinion shaft (Fig. 66). 9. Lubricate rear pinion bearing and install the pinion into the housing. 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. With a torque wrench tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 67). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3850 15. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 68). 16. Check pinion rotating torque with an inch pound torque wrench (Fig. 68). The pinion rotating torque should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. 18. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 19. Invert the differential case in the vise. 20. Install new ring gear bolts and alternately tighten to 156 Nm (115 ft. lbs.) (Fig. 69). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. 21. Install differential in housing and verify gear mesh, backlash and contact pattern. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle - C205F > Page 3851 22. Install axle shafts. 23. Install wheel and tire assemblies. 24. Install differential cover and fill with gear lubricant. 25. Install propeller shaft with reference marks aligned. 26. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F Seals and Gaskets: Service and Repair Front Axle - C205F C205F - FRONT AXLE / PINION SEAL REMOVAL 1. Raise and support the vehicle. 2. Remove skid plate, if equipped. 3. Remove both half shafts. 4. Mark the propeller shaft and pinion companion flange for installation reference. 5. Remove the front propeller shaft. 6. Rotate the pinion gear three or four times and verify pinion rotates smoothly. 7. Record pinion rotating torque with an inch pound torque wrench, for installation reference (Fig. 24). 8. Position Holder 6719 against the companion flange and install a four bolts and washers into the threaded holes and tighten the bolts. 9. Remove the pinion nut. 10. Remove the companion flange with Remover C-452 (Fig. 25). 11. Remove pinion seal with a pry tool or a slide hammer mounted screw. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3856 INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 26). 3. Install the companion flange onto the pinion with Installer C-371X and Holder 6719A. 4. Position holder 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. 5. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play (Fig. 27). CAUTION: Do not exceed the minimum tightening torque when installing the companion flange at this point. Damage to the collapsible spacer or bearings may result. 6. Tighten the nut to 271 Nm (200 ft. lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3857 7. Record the pinion rotating torque using a torque wrench. The rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.) (Fig. 28). 8. If the rotating torque is low, tighten the pinion nut in 3.5 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved. CAUTION: If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer. 9. Install propeller shaft with reference marks aligned. 10. Add gear lubricant to differential housing if necessary. 11. Install half shafts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3858 Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 8 1/4 Inch - REAR AXLE / PINION SEAL REMOVAL 1. Raise and support the vehicle. 2. Mark the universal joint, companion flange and pinion shaft for installation reference. 3. Remove companion flange bolts, and secure the shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove brake drums to prevent any drag. 6. Rotate companion flange three or four times and verify flange rotates smoothly. 7. Measure rotating torque of the pinion with a inch pound torque wrench and record the reading for installation reference. 8. Install bolts into two of the threaded holes in the companion flange 180° apart. 9. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 10. Remove the pinion nut and washer. 11. Remove companion flange with Remover C-452 (Fig. 24). 12. Remove pinion seal with a pry tool or slide hammer mounted screw. INSTALLATION NOTE: The outer perimeter of the seal is pre-coated with a special sealant. 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3859 2. Install new pinion seal with Installer C-4076-B and Handle C-4735-1 (Fig. 25) 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install bolts into two of the threaded holes in the companion flange 180° apart. 5. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so Holder 6719 is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719. 7. Install the pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result. 8. Hold companion flange with Holder 6719 and tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 26). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3860 9. Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.) (Fig. 27). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low use Holder 6719 to hold the companion flange (Fig. 26) and tighten pinion nut in 3.5 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The seal replacement is unacceptable if final pinion nut torque is less than 285 Nm (210 ft. lbs.). NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install the brake drums. 14. Check the differential housing lubricant level. 15. Install wheel and tire assemblies and lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3861 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 9 1/4 Inch - REAR AXLE / PINION SEAL REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assemblies. 3. Mark the universal joint, companion flange and pinion shaft for installation reference. 4. Remove propeller shaft from the companion flange. 5. Remove the brake drums to prevent any drag. 6. Rotate companion flange three or four times and record pinion rotating torque with an inch pound torque wrench. 7. 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. 8. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 9. Remove companion flange with Remover C-452 (Fig. 29). 10. Remove pinion seal with pry tool or slide hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3862 2. Install new pinion seal with Installer C-3860-A and Handle C-4171 (Fig. 30) 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result. 8. Hold companion flange with Holder 6719 and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.) (Fig. 31). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 3863 9. Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.) (Fig. 32). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low, use Holder 6719 to hold the companion flange and tighten pinion nut in 3.5 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install brake drums, wheel and tire assemblies and lower the vehicle. 14. Check the differential lubricant level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F Axle Bearing: Service and Repair Front Axle - C205F Removal and Installation / Front Axle Bearings/Bushings - C205F REMOVAL 1. Place transmission in neutral. 2. Raise and support vehicle. 3. Remove half shaft from vehicle. 4. Remove skid plate, if equipped. 5. Clean axle seal area. 6. Remove axle shaft O-ring. 7. Remove axle shaft. 8. Remove axle shaft seal. 9. Install axle shaft bearing Remover C-4660-A in the bearing (Fig. 21). Then tighten the nut to spread the remover in the bearing. 10. Install the bearing remove cup, bearing and nut (Fig. 22). Then tighten the nut to draw the bearing out. 11. Inspect the axle shaft tube bore for roughness and burrs. Remove as necessary. INSTALLATION 1. Wipe the axle shaft tube bore clean. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 3869 2. Install axle shaft bearing with Installer 5063 and Handle C-4171 (Fig. 23). 3. Install a new axle shaft seal with Installer X402 and Handle C-4171. 4. Install the axle shaft and half shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 3870 Axle Bearing: Service and Repair Removal and Installation - Rear Axle Rear Axle - 8 1/4 Inch 8 1/4 Inch - Rear Axle Bearings REMOVAL 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 4. Remove axle shaft bearing with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig. 23). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. NOTE: Install bearing with part number against the installer. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735- 1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 6. Check and fill gear lubricant. 7. Install wheel and tire assembly. 8. Remove support and lower vehicle. Rear Axle - 9 1/4 Inch 9 1/4 Inch - Rear Axle Bearings REMOVAL 1. Remove axle shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 3871 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 24). 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 and Foot 6310-9 (Fig. 25). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 3872 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171 (Fig. 26). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat the lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735-1. 4. Install the axle shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3877 Axle Shaft: Description and Operation DESCRIPTION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3878 The two Constant Velocity (C/V) drive shafts are identical and interchangeable. They are comprised of three major components (Fig. 1): An inner, tripod C/V joint - A short, solid interconnecting shaft - An outer, Rzeppa C/V joint with stub shaft The inner tripod joints are attached to the axle shaft splines (Fig. 1). The outer joint is splined and mates with the hub bearing on the knuckle. The lubricant amounts included with replacement rubber boots are different for inner and outer C/V joints. Apply only the specified lubricant amount to each C/V joint. CAUTION: Proper CV joint boot sealing is critical for retaining the special lubricant. Prevent foreign material from entering and contaminating the CV joints. Mishandling a CV drive shaft can cause a boot to be punctured or damage within the joints. Always support both ends of the CV drive shaft during removal and installation to avoid damage. When replacing C/V drive shaft components, ensure that only exact replacements parts are installed. OPERATION The axle driveshafts are located on either side of the differential and transmits power to the drive wheels, while allowing for vertical movement in the vehicle's suspension. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3879 Axle Shaft: Testing and Inspection DIAGNOSIS AND TESTING - HALF SHAFT Check for grease in the vicinity of the inboard tri-pod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease,-resulting in inadequate lubrication of the joint. - Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: A torn seal boot on the inner or outer joint of the driveshaft assembly which has allowed the C/V joint to become damaged. - A loose or missing clamp on the inner or outer joint of the driveshaft assembly which has allowed the C/V joint to become damaged. - A damaged or worn driveshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: A worn or damaged driveshaft inner tripod joint. - A sticking tripod joint spider assembly (inner tri-pod joint only). - Improper wheel alignment. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: Foreign material (mud, etc.) packed on the back-side of the wheel(s). - Out of balance front tires or wheels. - Improper tire and/or wheel runout. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference Axle Shaft: Service and Repair Dana Axle Number Cross Reference New Model Number ............................................................................................................................. ..................................... Old Dana Model Number 174 ....................................................................................................................................................... .......................................................................... 28 181 ....................................................................... .......................................................................................................................................................... 30 186 .................................................................................................................................................. .................................................................... Super 30 194 .................................................................. .............................................................................................................................................................. . 35 198 ................................................................................................................................................ ...................................................................... Super 35 200 ................................................................ .............................................................................................................................................................. ... 36 216 .............................................................................................................................................. ................................................................................... 44 226 .............................................................. ........................................................................................................................................................ Super 44 229 ....................................................................................................................................... .......................................................................................... 50 248 ....................................................... .............................................................................................................................................................. ............ 60 267 ..................................................................................................................................... ............................................................................................ 70 286 ..................................................... .............................................................................................................................................................. .............. 80 First Letter of Suffix F .......................................................................................................................................................... ................................................................ Front R ................................................................................ ........................................................................................................................................... Rear Second Letter of Suffix B .......................................................................................................................................................... ................................................................ Beam I ................................................................................ ................................................................................................................................ Independent Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3882 Third Letter of Suffix I ............................................................................................................................................................ ................................................................. Iron A ................................................................................. ................................................................................................................................. Aluminum Examples: 248FBI ................................................................................................................................................. ................... Dana 60, Front, Beam Axle, Iron 186FIA .............................................................................................................................................. Dana Super 30, Front, Independent, Aluminum 226RBA ............................................................................................................................................... Dana Super 44, Rear, Beam Axle, Aluminum Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3883 Axle Shaft: Service and Repair Axle Half Shaft Removal and Installation - Front Axle Half Shaft REMOVAL 1. Raise the vehicle. 2. Remove wheel and tire assembly. 3. Remove the skid plate, if equipped. 4. Remove cotter pin, nut lock, and spring washer from the stub shaft. 5. Remove hub nut and washer from the stub shaft. 6. Remove brake caliper and rotor. 7. Remove ABS wheel speed sensor if equipped. 8. Remove hub bearing bolts and hub bearing from the knuckle (Fig. 1). 9. Support half shaft at the C/V joint housings. 10. Position two pry bars behind the inner C/V housing and disengage the C/V joint from the axle (Fig. 2). 11. Remove half shaft from the vehicle. INSTALLATION 1. Apply a light coating of wheel bearing grease on the axle splines. 2. Insert half shaft stub through the steering knuckle and onto the axle. Verify shaft snap-ring engages with the groove on the inside of the joint housing. 3. Clean hub bearing bore and hub bearing mating surface of all foreign materials. Apply light coating of grease to all mating surfaces. 4. Install hub bearing onto the axle half shaft and steering knuckle. 5. Install hub bearing bolts and tighten to specifications. 6. Install ABS wheel speed sensor, if equipped. 7. Install brake rotor and caliper. 8. Apply the brakes and tighten hub nut to 244 Nm (180 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3884 9. Install spring washer, nut lock and cotter pin. 10. Install skid plate, if equipped. 11. Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3885 Axle Shaft: Service and Repair Removal and Installation - Front Axle Shaft Axle Shaft Removal and Installation / Front Axle Shaft - C205F REMOVAL Front Axle - C205F 1. Place transmission in neutral. 2. Raise and support vehicle. 3. Remove half shaft from vehicle. 4. Remove skid plate, if equipped. 5. Clean axle seal area. 6. Remove snap ring from the axle shaft. 7. Remove axle with Remove X420A and Slide Hammer C-3752 (Fig. 20). INSTALLATION NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Insert axle shaft through seal, bearing, and engage it into side gear splines. Push firmly on the axle shaft to engage the snap-ring. 3. Check the differential fluid level and add fluid if necessary. 4. Install skid plate, if necessary. 5. Install half shaft. 6. Remove support and lower vehicle. Axle Shaft Bearings/Bushings Removal and Installation / Front Axle Bearings/Bushings - C205F REMOVAL 1. Place transmission in neutral. 2. Raise and support vehicle. 3. Remove half shaft from vehicle. 4. Remove skid plate, if equipped. 5. Clean axle seal area. 6. Remove axle shaft O-ring. 7. Remove axle shaft. 8. Remove axle shaft seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3886 9. Install axle shaft bearing Remover C-4660-A in the bearing (Fig. 21). Then tighten the nut to spread the remover in the bearing. 10. Install the bearing remove cup, bearing and nut (Fig. 22). Then tighten the nut to draw the bearing out. 11. Inspect the axle shaft tube bore for roughness and burrs. Remove as necessary. INSTALLATION 1. Wipe the axle shaft tube bore clean. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3887 2. Install axle shaft bearing with Installer 5063 and Handle C-4171 (Fig. 23). 3. Install a new axle shaft seal with Installer X402 and Handle C-4171. 4. Install the axle shaft and half shaft. Axle Shaft Seals Removal and Installation / Front Axle Seals - C205F REMOVAL 1. Remove half shaft and axle shaft. 2. Remove the axle shaft seal with a small pry bar. INSTALLATION 1. Wipe the axle shaft tube bore clean. 2. Install a new axle shaft seal with Installer X402 and Handle C-4171. 3. Install the axle shaft and half shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3888 Axle Shaft: Service and Repair Rear Axle - 8 1/4 Axle Shaft Removal and Installation - Rear Axle Shaft 8 1/4 inch REMOVAL 1. Place transmission in neutral and raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake drum. 4. Remove differential cover and drain lubricant. 5. Rotate differential case to access the pinion shaft lock screw. Remove lock screw and pinion shaft from differential case (Fig. 20). 6. Push axle shaft inward then remove axle shaft C-lock (Fig. 21). 7. Remove axle shaft being careful not to damage shaft bearing and seal. 8. Inspect axle shaft seal for leakage or damage. 9. Inspect axle shaft bearing contact surface for signs of brinelling, galling and pitting. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3889 2. Insert C-lock in end of axle shaft. Push axle shaft outward to seat C-lock in side gear. 3. Insert pinion shaft into differential case and through thrust washers and differential pinions. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). 5. Install cover and fill with gear lubricant to the bottom of the fill plug hole. 6. Install brake drum. 7. Install wheel and tire assemblies. 8. Remove support and lower vehicle. Axle Shaft Seals 8 1/4 Inch - Rear Axle Seals REMOVAL 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 22). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 4. Install the axle shaft. 5. Check and fill gear lubricant. 6. Install wheel and tire assembly. 7. Remove support and lower vehicle. Axle Shaft Bearings 8 1/4 Inch - Rear Axle Bearings REMOVAL 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3890 4. Remove axle shaft bearing with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig. 23). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. NOTE: Install bearing with part number against the installer. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735- 1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 6. Check and fill gear lubricant. 7. Install wheel and tire assembly. 8. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3891 Axle Shaft: Service and Repair Rear Axle - 9 1/4 Axle Shaft Removal and Installation - Rear Axle Shaft 9 1/4 inch REMOVAL 1. Place transmission in neutral. 2. Raise and support the vehicle. 3. Remove wheel and tire assembly. 4. Remove brake drum. 5. Remove differential housing cover and drain lubricant. 6. Rotate differential case so pinion mate shaft lock screw is accessible. Remove lock screw and pinion mate shaft from differential case (Fig. 22). 7. Push axle shaft inward and remove axle shaft C-lock from the axle shaft (Fig. 23). 8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal in the axle tube. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal. 2. Insert C-lock in end of axle shaft then push axle shaft outward to seat C-lock in side gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3892 3. Insert pinion shaft into differential case and through thrust washers and differential pinions. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). 5. Install differential cover and fill with gear lubricant. 6. Install brake drum. 7. Install wheel and tire. 8. Remove support and lower vehicle. Axle Shaft Seals 9 1/4 Inch - Rear Axle Seals REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 27). 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- 1 (Fig. 28). When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft. Axle Shaft Bearings Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3893 9 1/4 Inch - Rear Axle Bearings REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 24). 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 and Foot 6310-9 (Fig. 25). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3894 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171 (Fig. 26). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat the lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735-1. 4. Install the axle shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 3895 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer Constant Velocity Joint: Service and Repair CV Joint/Boot - Outer CV Joint / Boot - Outer REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. 2. Remove clamps with a cut-off wheel or grinder (Fig. 3). CAUTION: Do not damage C/V housing or half shaft. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring. 5. Spread snap ring and slide the joint off the shaft (Fig. 4). 6. Slide boot off the shaft and discard old boot. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3900 7. Mark alignment marks on the inner race/hub, bearing cage and housing with dabs of paint (Fig. 5). 8. Clamp C/V joint in a vertical position in a in soft jawed vise. 9. Press down one side of the bearing cage to gain access to the ball at the opposite. 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 from the bearing cage (Fig. 6). 11. Repeat step above until all six balls are removed from the bearing cage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3901 12. Lift cage and inner race upward and out from the housing (Fig. 7). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage (Fig. 8). INSTALLATION NOTE: If ON joint is worn, replace entire ON joint and boot. 1. Apply a light coat of grease to the C/V joint components before assembling them. 2. Align the inner race, cage and housing according to the alignment reference marks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3902 3. Insert the inner race into the cage (Fig. 9) and rotate race into the cane. 4. Rotate the inner race/hub in the cage (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3903 5. Insert cage into the housing (Fig. 11). Rotate the cage 90° into the housing (Fig. 12). 6. Apply the lubricant included with the replacement boot to the ball races. Spread the lubricant equally between all the races. 7. Tilt inner race/hub and cage and install the balls (Fig. 13). 8. Place new clamps onto new boot and slide boot onto the shaft to its original position. 9. Apply the rest of lubricant to the C/V joint and boot. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3904 10. Install the joint onto the shaft. Push the joint onto the shaft until the snap ring seats in the groove (Fig. 14). Pull on the joint to verify the span ring has engaged. 11. Position the boot on the joint in its original position. Ensure that the boot is not twisted and remove any excess air. 12. Secure both boot clamps (Fig. 15) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the toll are closed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3905 Constant Velocity Joint: Service and Repair CV Joint/Boot - Inner CV Joint / Boot - Inner REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. 2. Remove clamps with a cut-off wheel or grinder (Fig. 16). CAUTION: Do not damage ON housing or half shaft with cut-off wheel or grinder. 3. Remove housing from the half shaft (Fig. 17) and slide boot down shaft. 4. Remove housing bushing from the housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3906 5. Remove tripod snap ring (Fig. 18). 6. Remove tripod 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 1. Slide new boot down the half shaft. 2. Install tripod and tripod snap ring on the half shaft (Fig. 19). 3. Pack grease supplied with the joint/boot into the housing and boot. 4. Coat tripod with supplied grease. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3907 5. Install new bushing (Fig. 20) onto the housing. 6. Insert the tripod and shaft in the housing. 7. Position the boot on the joint in its original position (Fig. 21). NOTE: Verify boot is not twisted and remove any excess air. 8. Secure both boot clamps with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Page 3908 Half Shaft Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer Constant Velocity Joint Boot: Service and Repair CV Joint/Boot - Outer CV Joint / Boot - Outer REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. 2. Remove clamps with a cut-off wheel or grinder (Fig. 3). CAUTION: Do not damage C/V housing or half shaft. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring. 5. Spread snap ring and slide the joint off the shaft (Fig. 4). 6. Slide boot off the shaft and discard old boot. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3913 7. Mark alignment marks on the inner race/hub, bearing cage and housing with dabs of paint (Fig. 5). 8. Clamp C/V joint in a vertical position in a in soft jawed vise. 9. Press down one side of the bearing cage to gain access to the ball at the opposite. 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 from the bearing cage (Fig. 6). 11. Repeat step above until all six balls are removed from the bearing cage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3914 12. Lift cage and inner race upward and out from the housing (Fig. 7). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage (Fig. 8). INSTALLATION NOTE: If ON joint is worn, replace entire ON joint and boot. 1. Apply a light coat of grease to the C/V joint components before assembling them. 2. Align the inner race, cage and housing according to the alignment reference marks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3915 3. Insert the inner race into the cage (Fig. 9) and rotate race into the cane. 4. Rotate the inner race/hub in the cage (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3916 5. Insert cage into the housing (Fig. 11). Rotate the cage 90° into the housing (Fig. 12). 6. Apply the lubricant included with the replacement boot to the ball races. Spread the lubricant equally between all the races. 7. Tilt inner race/hub and cage and install the balls (Fig. 13). 8. Place new clamps onto new boot and slide boot onto the shaft to its original position. 9. Apply the rest of lubricant to the C/V joint and boot. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3917 10. Install the joint onto the shaft. Push the joint onto the shaft until the snap ring seats in the groove (Fig. 14). Pull on the joint to verify the span ring has engaged. 11. Position the boot on the joint in its original position. Ensure that the boot is not twisted and remove any excess air. 12. Secure both boot clamps (Fig. 15) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the toll are closed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3918 Constant Velocity Joint Boot: Service and Repair CV Joint/Boot - Inner CV Joint / Boot - Inner REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. 2. Remove clamps with a cut-off wheel or grinder (Fig. 16). CAUTION: Do not damage ON housing or half shaft with cut-off wheel or grinder. 3. Remove housing from the half shaft (Fig. 17) and slide boot down shaft. 4. Remove housing bushing from the housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3919 5. Remove tripod snap ring (Fig. 18). 6. Remove tripod 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 1. Slide new boot down the half shaft. 2. Install tripod and tripod snap ring on the half shaft (Fig. 19). 3. Pack grease supplied with the joint/boot into the housing and boot. 4. Coat tripod with supplied grease. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Joint/Boot - Outer > Page 3920 5. Install new bushing (Fig. 20) onto the housing. 6. Insert the tripod and shaft in the housing. 7. Position the boot on the joint in its original position (Fig. 21). NOTE: Verify boot is not twisted and remove any excess air. 8. Secure both boot clamps with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3921 Half Shaft Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Removal and Installation - Front Axle Seals and Gaskets: Service and Repair Removal and Installation - Front Axle Removal and Installation / Front Axle Seals - C205F REMOVAL 1. Remove half shaft and axle shaft. 2. Remove the axle shaft seal with a small pry bar. INSTALLATION 1. Wipe the axle shaft tube bore clean. 2. Install a new axle shaft seal with Installer X402 and Handle C-4171. 3. Install the axle shaft and half shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Removal and Installation - Front Axle > Page 3926 Seals and Gaskets: Service and Repair Removal and Installation - Rear Axle Rear Axle - 9 1/4 Inch 9 1/4 Inch - Rear Axle Seals REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 27). 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- 1 (Fig. 28). When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft. Rear Axle - 8 1/4 Inch 8 1/4 Inch - Rear Axle Seals REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Removal and Installation - Front Axle > Page 3927 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 22). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 4. Install the axle shaft. 5. Check and fill gear lubricant. 6. Install wheel and tire assembly. 7. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Half Shaft Nut ...................................................................................................................................... .............................................. 244 Nm (180 Ft Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Description and Operation Center Support: Description and Operation Center Bearing DESCRIPTION The two-piece propeller shaft uses a center bearing to support the shafts. The bearing is used to support the shafts where they are joined together. The bearing is insulated in rubber and is mounted to the frame crossmember. OPERATION The propeller shaft center bearing serves to divide the required propeller shaft length into two smaller shafts, which has several inherent advantages. Having two short propeller shafts instead of one long shaft decreases the chance of unwanted noise and vibrations. The shorter shafts are easier to balance and serve to increase ground clearance while maintaining acceptable driveline angles. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Description and Operation > Page 3939 Center Support: Adjustments CENTER BEARING ADJUSTMENT Drive away shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Description and Operation > Page 3940 Center Support: Service and Repair CENTER BEARING / REMOVAL 1. Remove rear propeller shaft. 2. Remove slip joint boot clamp and separate the two half-shafts. 3. Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. 4. Position Bearing Splitter Tool 1130 between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. 5. Set shaft in press and press bearing off the shaft. INSTALLATION 1. Install new slinger on shaft and drive into position with appropriate installer tool. 2. Install new center bearing on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. 3. Clean shaft splines and apply a coat of multipurpose grease. 4. Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp. 5. Install propeller shaft in vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Propeller Shaft Specifications RUNOUT SPECIFICATIONS Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 3944 Drive/Propeller Shaft: Description and Operation DESCRIPTION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 3945 A propeller shaft (Fig. 1), (Fig. 2), and (Fig. 3) is the shaft which connects the transmission/transfer case to the axle differential. This is the link through which the engine power is transmitted to the axle. The propeller shaft is designed and built with the yoke lugs in line with each other which is called zero phasing. This design produces the smoothest running condition, an out-of-phase shaft can cause a vibration. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. Use the exact replacement parts when installing the propeller shafts. The use of the correct replacement parts helps to ensure safe operation. All fasteners must be torqued to the specified values for safe operation. Also make alignment reference marks (Fig. 4) the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possible vibration. CAUTION: Do not allow the propeller shaft to drop or hang from any propeller shaft joint during removal. Attach the propeller shaft to the vehicle underside with wire to prevent damage to the joints. OPERATION The propeller shaft must operate through constantly changing relative angles between the transmission and axle. It must also be capable of changing length while transmitting torque. The axle rides suspended by springs in a floating motion. The propeller shaft must be able to change operating angles when going over various road surfaces. This is accomplished through universal joints/constant velocity joint, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion. Before undercoating a vehicle, the propeller shaft and the U-joints should be covered to pre-vent an out-of-balance condition and driveline vibration. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 3946 CAUTION: Use original equipment replacement parts for attaching the propeller shafts. The specified torque must always be applied when tightening the fasteners. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration Drive/Propeller Shaft: Testing and Inspection Vibration Diagnosis and Testing - Propeller Shaft VIBRATION Tires that are out-of-round or wheels that are unbalanced, will cause a low frequency vibration. Brake drums that are unbalanced will cause a harsh, low frequency vibration. Driveline vibration can also result from loose or damaged engine mounts. Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range, is not usually caused by a propeller shaft being unbalanced. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 3949 Drive/Propeller Shaft: Testing and Inspection Balance Diagnosis and Testing - Propeller Shaft BALANCE NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: 1. Raise the vehicle. 2. Clean all the foreign material from the propeller shaft and the universal joints. 3. Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. 4. Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with the shaft. 5. Check the universal joint clamp screws torque. 6. Remove the wheels and tires. Install the wheel lug nuts to retain the brake drums or rotors. 7. Mark and number the shaft six inches from the yoke end at four positions 90° apart. 8. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position 1 (Fig. 1). 10. Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test. 11. If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft. 12. If the vibration decreased, install a second clamp (Fig. 2) and repeat the test. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 3950 13. If the additional clamp causes an additional vibration, separate the clamps (1/2 inch above and below the mark). Repeat the vibration test (Fig. 3). 14. Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. 15. If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. 16. Install the wheel and tires. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 3951 Drive/Propeller Shaft: Testing and Inspection Runout Diagnosis and Testing - Propeller Shaft RUNOUT 1. Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. 2. The dial indicator must be installed perpendicular to the shaft surface. 3. Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements. 4. Refer to Runout Specifications. 5. If the propeller shaft runout is out of specification, remove the propeller shaft, index the shaft 180°, and re-install the propeller shaft. Measure shaft runout again. 6. If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation. 7. If the propeller shaft runout is not within specifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout. 8. Replace the propeller shaft if the runout still exceeds the limits. RUNOUT SPECIFICATIONS Front of Shaft........................................................................................................................................ .............................................. 0.020 inch (0.50 mm) Center of Shaft..................................................................................................................................... ............................................... 0.025 inch (0.63 mm) Rear of Shaft........................................................................................................................................ ............................................... 0.020 inch (0.50 mm) NOTE: Measure front/rear runout approximately 3 inches (76 mm) from the weld seam at each end of the shaft tube for tube lengths over 30 inches. For tube lengths under 30 inches, the maximum allowed runout is 0.020 inch (0.50 mm) for the full length of the tube. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 3952 NOISE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front Drive/Propeller Shaft: Service and Repair Propeller Shaft - Front Removal and Installation Propeller Shaft - Front REMOVAL 1. Position transmission and transfer case to their neutral positions. Raise and support vehicle. Remove skid plate, if equipped. 2. Mark a line across the transfer case flange and C/V for installation reference. 3. Mark a line across the propeller shaft flange yoke and front axle companion flange (Fig. 9) for installation reference. 4. Remove companion flange bolts (Fig. 10). 5. Remove transfer case flange bolts and remove propeller shaft. INSTALLATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3955 1. Install propeller shaft with all reference marks aligned. 2. Loosely install bolts to C/V and transfer case companion flange. 3. Install bolts to companion flange and flange yoke and tighten to 108 Nm (80 ft. lbs.). 4. Tighten bolts to transfer case companion flange to 30.5 Nm (22.5 ft. lbs.). 5. Install skid plate, if equipped. 6. Lower vehicle and road test to verify repair. Standard Procedure - Propeller Shaft Angle STANDARD PROCEDURES - PROPELLER SHAFT ANGLE To accurately check driveline alignment, raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. PROPELLER SHAFT ANGLE 1. Remove any external bearing snap rings, if equipped, from universal joint so protractor base sits flat. 2. Rotate the shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always make measurements from front to rear and from the same side of the vehicle. 3. Place Inclinometer 7663 (J-23498A) on yoke bearing (A) parallel to the shaft (Fig. 4). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the transmission or Output Yoke Angle (A). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3956 4. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig. 5). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. NOTE: This measurement will give you the Propeller Shaft Angle (C). 5. Subtract smaller figure from larger (C minus A) to obtain Transmission Output Operating Angle. 6. Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing parallel to the shaft (Fig. 6). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the pinion shaft or Input Yoke Angle (B). 7. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3957 NOTE: Refer to rules given below and the example in (Fig. 7) for additional information. - Good cancellation of U-joint operating angles (within 1°). - Operating angles less than 3°. - At least 1/2 of one degree continuous operating (propeller shaft) angle. TWO-PIECE PROPELLER SHAFT The procedure to measure the propeller shaft angles involved with a two-piece (Fig. 8) propeller shaft is the same as those for a one-piece propeller shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3958 Drive/Propeller Shaft: Service and Repair Propeller Shaft - Rear Removal and Installation Propeller Shaft - Rear REMOVAL 1. Place the transmission into the Neutral position. 2. Raise and support vehicle on safety stands. 3. Mark a line across the axle companion flange and propeller shaft flange yoke (Fig. 11) for installation reference. 4. Mark an outline of the center bearing on the support bracket for installation reference, if equipped. 5. Mark an outline of the heat shield on the center bearing for installation reference, if equipped. 6. Remove center bearing and heat shield bolts, if equipped. 7. Remove companion flange bolts. 8. Slide slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft (Fig. 12). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3959 INSTALLATION 1. Slide the slip yoke onto the transmission, or transfer case, output shaft. 2. Align and install the center bearing and heat shield to the support bracket, if necessary. Install the bolts and tighten to 68 Nm (50 ft. lbs.). 3. Align companion flange reference mark with flange yoke mark. 4. Install companion flange bolts and tighten to 108 Nm (80 ft. lbs.). 5. Lower the vehicle. Standard Procedure - Propeller Shaft Angle STANDARD PROCEDURES - PROPELLER SHAFT ANGLE To accurately check driveline alignment, raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. PROPELLER SHAFT ANGLE 1. Remove any external bearing snap rings, if equipped, from universal joint so protractor base sits flat. 2. Rotate the shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always make measurements from front to rear and from the same side of the vehicle. 3. Place Inclinometer 7663 (J-23498A) on yoke bearing (A) parallel to the shaft (Fig. 4). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the transmission or Output Yoke Angle (A). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3960 4. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig. 5). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. NOTE: This measurement will give you the Propeller Shaft Angle (C). 5. Subtract smaller figure from larger (C minus A) to obtain Transmission Output Operating Angle. 6. Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing parallel to the shaft (Fig. 6). Center bubble in sight glass and record measurement. NOTE: This measurement will give you the pinion shaft or Input Yoke Angle (B). 7. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Front > Page 3961 NOTE: Refer to rules given below and the example in (Fig. 7) for additional information. - Good cancellation of U-joint operating angles (within 1°). - Operating angles less than 3°. - At least 1/2 of one degree continuous operating (propeller shaft) angle. TWO-PIECE PROPELLER SHAFT The procedure to measure the propeller shaft angles involved with a two-piece (Fig. 8) propeller shaft is the same as those for a one-piece propeller shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the companion yoke after removing the cardan joint from the tube yoke. Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. 1. Remove the propeller shaft. 2. Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. 3. Remove snap rings from both sides of yoke (Fig. 13). 4. Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. 5. Position the yoke with the grease fitting, if equipped, pointing up. 6. Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 14). 7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 3965 8. To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 15). CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the companion yoke after removing the cardan joint from the tube yoke. 1. Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. 2. Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 16). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 3966 3. Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 17). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. 4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. 6. Repeat Step 3 and Step 4 to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 7. Add grease to lube fitting, if equipped. 8. Install the propeller shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Bolts, Drive plate to crankshaft ............................................................................................................ ..................................................... 75 Nm (55 ft lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 3970 Flex Plate: Service and Repair REMOVAL 1. Remove the transmission. 2. Remove the bolts and flexplate. INSTALLATION 1. Position the flexplate onto the crankshaft and install the bolts hand tight. 2. Tighten the flexplate retaining bolts to 60 Nm (45 ft. lbs.) in the sequence shown (Fig. 71). 3. Install the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Clutch Torque Specifications Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3974 Flywheel: Description and Operation DESCRIPTION The flywheel (Fig. 12) is a heavy plate bolted to the rear of the crankshaft. The flywheel incorporates the ring gear 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. OPERATION The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain. The crankshaft has the tendency to attempt to speed up and slow down in response to the cylinder firing pulses. The flywheel dampens these impulses by absorbing energy when the crank-shaft speeds and releasing the energy back into the system when the crankshaft slows down. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3975 Flywheel: Testing and Inspection DIAGNOSIS AND TESTING - FLYWHEEL Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 inch). 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. However, 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 inch). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 inch). 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 Lock And Seal. Tighten flywheel bolts to specified torque only. Over tightening can distort the flywheel hub causing runout. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3976 Flywheel: Service and Repair Refer to main system Clutch / Service and Repair for complete removal, disassembly, cleaning, inspection, assembly, and installation procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3982 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3983 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3987 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 3992 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 3993 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > M/T - Clutch Housing and Structural Cover Installation Bell Housing: Technical Service Bulletins M/T - Clutch Housing and Structural Cover Installation NUMBER: 21-004-02 GROUP: Transmission DATE: Dec. 13, 2002 SUBJECT: 3.7L, 4.7L, and 5.7L Clutch Housing and Structural Cover Installation MODELS: 2000 - 2003 (AN) Dakota 2002 - 2003 (DR) Ram Pickup NOTE: THIS BULLETIN APPLIES TO 2000 - 2003 (AN) DAKOTA TRUCKS EQUIPPED WITH A 4.7L ENGINE (SALES CODE EVA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36). 2002 - 2003 (DR) RAM TRUCK EQUIPPED WITH 3.7L, 4.7L OR 5.7L ENGINE (SALES CODE EKG, EVA, OR EZA) AND 5 SPEED MANUAL TRANSMISSION (SALES CODE A36, A64, OR A74). DISCUSSION: The clutch housing maintains alignment between the crankshaft and transmission input shaft. The structural cover provides additional powertrain stiffness and reduces noise and vibration. If either one is bolted to the engine or to each other, in the wrong sequence, drivetrain misalignment could result. Misalignment could result in reduced life expectancy of drivetrain components such as the clutch disc assembly, pilot bearing, clutch release components, and transmission. If misalignment is suspected and the clutch housing bore runout is found to be excessive using the diagnostic procedures in the service manual or if the clutch housing and structural cover has been removed for any reason, the components should be installed using the following Repair Procedure. REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect the negative battery cable. 3. Remove the transmission as outlined in the service information available in MDS2 or the 2003 DR Ram Truck Service Manual (Publication No. 81-370-03059) page 21-43 (5.7L only). 4. Clean the clutch housing mounting surface of the engine block using Mopar Engine Degreaser pin 04318040 (or equivalent). 5. Verify that the clutch housing alignment dowels are in good condition and properly seated. CAUTION: THE STRUCTURAL COVER MUST BE INSTALLED AS DESCRIBED IN THE FOLLOWING STEPS. FAILURE TO DO SO WILL CAUSE SEVERE DAMAGE TO THE COVER, AND ENGINE NOISE. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > M/T - Clutch Housing and Structural Cover Installation > Page 3999 6. Align and install the clutch housing and the structural cover on the back of the block in the following sequence: a. Install four (4) clutch housing to engine (3/8 in. diameter) bolts located at the top of the clutch housing and torque to 40.6 Nm (30 lb ft). b.Install dust shield (1/4 in. diameter) bolt and torque to 4.5 Nm (40 in. lbs.). c. Position structural cover flush to the engine block and the clutch housing, and hold in position while hand starting the fasteners. CAUTION: THE STRUCTURAL COVER MUST BE HELD TIGHTLY AGAINST THE CORNER FORMED BY THE ENGINE AND THE TRANSMISSION CLUTCH HOUSING DURING TIGHTENING SEQUENCE. FAILURE TO DO SO MAY CAUSE DAMAGE TO THE COVER AND ENGINE NOISE. d. Tighten two (2) structural cover fasteners (Item 3 & 7) (Fig. 1) to the clutch housing and torque to 5 - 11 Nm (50-100 in. lbs). e. Install four (4) structural cover fasteners (Items 2, 4, 5, & 6) (Fig. 1) to the engine and torque to 5 - 11 Nm (50-100 in. lbs). 7. Torque the six (6) structural cover bolts installed in steps d & e above in the following order: a. Torque the bolt that is closest to the rear face of block on the passenger side (Item 4) (Fig. 1) to 54 Nm (40 ft. lbs.). b. Torque the bolt that is closest to the front face of the block on the driver side (Item 5) (Fig. 1) to 54 Nm (40 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > M/T - Clutch Housing and Structural Cover Installation > Page 4000 c. Torque the bolt that is closest to the front face of the block on the passenger side (Item 2) (Fig. 1) to 54 Nm (40 ft. lbs.). d. Torque the bolt that is closest to the rear face of the block on the driver side (Item 6) (Fig. 1) to 54 Nm (40 ft. lbs.). e. Torque two (2) structural cover bolts to the clutch housing (Item 3 & 7) to 54 Nm (40 ft. lbs.). 8. Install the (2 - 5.7L) (4 - 3.7L & 4.7L) engine to housing bolts (7/16 in. diameter bolts) and torque to 68 Nm (50 ft. lbs.), as a last step. 9. Install transmission (5.7L only) and transfer case if equipped. NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK WHEN THE PROCEDURE IS COMPLETE. 10. Reconnect the negative battery cable. POLICY: Information Only. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > Page 4001 Bell Housing: Specifications A Bolts ................................................................................................................................................. .................................................... 38 Nm (28 ft. lbs.) Upper Transmission B Bolts ................................................................................................................ .................................................... 75 Nm (55 ft. lbs.) Lower Transmission C Bolts ................................................................................................................ .................................................... 50 Nm (37 ft. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > Page 4002 Bell Housing: Testing and Inspection DIAGNOSIS AND TESTING - CLUTCH HOUSING Clutch housing alignment is important to proper clutch operation. The housing maintains alignment between the crankshaft and transmission input shaft. Misalignment can cause clutch noise, hard shifting, incomplete release and chatter. It can also result in premature wear of the pilot bearing, cover release fingers and clutch disc. In severe cases, misalignment can also cause premature wear of the transmission input shaft and front bearing. Housing misalignment is generally caused by incorrect seating on the engine or transmission, loose housing bolts, missing alignment dowels, or housing damage. Infrequently, misalignment may also be caused by housing mounting surfaces that are not completely parallel. Misalignment can be corrected with shims. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Technical Service Bulletins > Page 4003 Bell Housing: Service and Repair CLUTCH HOUSING / REMOVAL 1. Raise vehicle and support vehicle. 2. Remove transmission and clutch housing as assembly. 3. Remove release bearing, release fork and fork boot from input shaft and clutch housing. 4. Remove bolts attaching clutch housing to transmission (Fig. 7). INSTALLATION 1. Clean mounting surfaces of transmission and clutch housing. Use a wire brush if necessary followed by a wax and grease remover, or similar solvent. Also clean engine block surface as well. 2. Position clutch housing on transmission and install housing attaching bolts. Tighten A bolts to 38 Nm (28 ft. lbs.). 3. Install release fork pivot ball stud to housing, if necessary. 4. Lubricate release bearing bore, release fork contact surfaces, and release fork pivot stud with Mopar high temperature bearing grease. Also lubricate transmission input shaft splines, pilot hub and bearing retainer slide surface with light coat of same grease. 5. Install release fork, bearing, and boot in housing. Be sure release fork boot is properly seated in housing. 6. Install transmission. Tighten the upper transmission B bolts to 75 Nm (55 ft. lbs.). Tighten all lower transmission C bolts to 50 Nm (37 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Specifications Differential Fluid - M/T: Specifications Differential Assembly Fluid Front Axle - C205F .............................................................................................................................................................. ................................................ 1.66 Liters (3.5 pts.) Rear Axle - 9 1/4 Inch .............................................................................................................................................................. ............................................ 2.32 Liters (4.9 pts.) ** Rear Axle - 8 1/4 Inch .............................................................................................................................................................. ........................................... 2.22 Liters (4.7 pts.) ** ** With Trac-Lok add 148 ml (5 oz) of friction modifier. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > NV1500 - Manual Transmission Extension Housing: Service and Repair NV1500 - Manual Transmission EXTENSION HOUSING SEAL / NV1500 Manual Transmission REMOVAL 1. Raise and support vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with Remover C-3985-B (Fig. 93) from transmission housing. INSTALLATION 1. Place seal in position on transmission housing. 2. Drive new seal into transmission housing with Installer C-3972-A and Handle C-4171 (Fig. 94). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. 4. Install propeller shaft with reference marks aligned. 5. Remove support and lower vehicle. 6. Check transmission fluid level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > NV1500 - Manual Transmission > Page 4012 Extension Housing: Service and Repair NV3500 - Manual Transmission Extension Housing Seal EXTENSION HOUSING SEAL / NV3550 Manual Transmission REMOVAL 1. Raise and support vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with Remover C-3985-B (Fig. 126) from transmission housing. INSTALLATION 1. Place seal in position on transmission housing. 2. Drive new seal into transmission housing with Installer C-3972-A and Handle C-4171 (Fig. 127). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. 4. Install propeller shaft with reference marks aligned. 5. Remove support and lower vehicle. 6. Check transmission fluid level. Extension Housing Bushing EXTENSION HOUSING BUSHING / NV3550 Manual Transmission REMOVAL 1. Raise and support vehicle. 2. Mark reference lines on the propeller shaft and remove the shaft. 3. Remove housing yoke seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > NV1500 - Manual Transmission > Page 4013 4. Insert Remover 6957 into rear housing and tighten tool to bushing and remove bushing (Fig. 128). INSTALLATION 1. Align bushing oil hole with oil slot in rear housing. 2. Tap bushing into place with Installer 6951 and Handle C-4171. 3. Install new oil seal in housing using Installer C-3972-A (Fig. 129). 4. Install propeller shaft with reference marks aligned. 5. Remove support and lower vehicle. 6. Check transmission fluid level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications NV1500 Manual Transmission Drain/Fill Plug....................................................................................................................................... .....................................................34 Nm (25 ft. lbs.) NV3500 Manual Transmission Drain/Fill Plug....................................................................................................................................... .........................................9 - 27 Nm (14 - 20 ft. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications > Page 4017 Fill Plug: Locations NV1500 Manual Transmission The drain plug in on the bottom of the transmission and fill plug is on the side. NV3500 Manual Transmission The drain plug in on the bottom of the transmission and fill plug is on the side. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications NV1500 - Manual Transmission NV1500 Manual Transmission ............................................................................................................ ................................................... 2.3Liters (4.86 pts) Approximate dry fill or fill to bottom edge of the fill plug hole NV3500 - Manual Transmission NV3500 Manual Transmission ............................................................................................................................................................. 1.98 Liters (4.18 pts) Approximate dry fill or fill to bottom edge of the fill plug hole. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4022 Fluid - M/T: Fluid Type Specifications Mopar Manual Transmission Lubricant is recommended or equivalent for use in the manual transmissions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 4023 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV1500 - Manual Transmission Seals and Gaskets: Service and Repair NV1500 - Manual Transmission EXTENSION HOUSING SEAL / NV1500 Manual Transmission REMOVAL 1. Raise and support vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with Remover C-3985-B (Fig. 93) from transmission housing. INSTALLATION 1. Place seal in position on transmission housing. 2. Drive new seal into transmission housing with Installer C-3972-A and Handle C-4171 (Fig. 94). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. 4. Install propeller shaft with reference marks aligned. 5. Remove support and lower vehicle. 6. Check transmission fluid level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV1500 - Manual Transmission > Page 4028 Seals and Gaskets: Service and Repair NV3500 - Manual Transmission EXTENSION HOUSING SEAL / NV3550 Manual Transmission REMOVAL 1. Raise and support vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with Remover C-3985-B (Fig. 126) from transmission housing. INSTALLATION 1. Place seal in position on transmission housing. 2. Drive new seal into transmission housing with Installer C-3972-A and Handle C-4171 (Fig. 127). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. 4. Install propeller shaft with reference marks aligned. 5. Remove support and lower vehicle. 6. Check transmission fluid level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4051 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4052 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4053 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4054 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4055 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4056 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4057 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4058 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4062 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4063 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4064 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4065 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4070 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4071 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4072 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4073 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4074 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4080 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4081 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4082 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4083 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4087 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4088 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4089 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4090 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4099 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4100 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4101 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4102 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4105 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4106 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4107 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4110 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4111 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4112 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4113 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4114 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4118 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4119 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4124 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4125 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4126 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4129 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4132 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 4140 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 4143 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 4144 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) 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 > NV233 Transfer Case > Page 4145 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 4149 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4152 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4153 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4154 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations > Page 4160 Transfer Case Shift Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Shift Motor: Description and Operation NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 78) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case > Page 4163 Transfer Case Shift Motor: Description and Operation NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 85) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case Transfer Case Shift Motor: Service and Repair NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 79) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 80) 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 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4166 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to .........122 - 176 Nm (90 -130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4167 Transfer Case Shift Motor: Service and Repair NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 86) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 87) 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 Lock & Seal or Loctite(tm) 242 to replenish Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4168 the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4172 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4173 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4174 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4175 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4176 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications Fluid - Transfer Case: Mechanical Specifications NV233 - Transfer Case Plug, Drain/Fill ............................................................................................... ............................................................................ 41 - 54 Nm (30 - 40 ft. lbs.) NV244 - Transfer Case Plug, Drain/Fill ............................................................................................... ............................................................................ 41 - 54 Nm (30 - 40 ft. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 4181 Fluid - Transfer Case: Capacity Specifications NV233 - Transfer Case Transfer Case Fluid ....................................................................................... ....................................................................................... 1.18 Liters (2.5 pts.) NV244 - Transfer Case Transfer Case Fluid ....................................................................................... ..................................................................................... 1.35 Liters (2.85 pts.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 4182 Fluid - Transfer Case: Fluid Type Specifications NV233 ....................................................................................................................................... Mopar ATF +4, type 9602, Automatic Transmission Fluid NV244 ....................................................................................................................................... Mopar ATF +4, type 9602, Automatic Transmission Fluid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Standard Procedure - NV233 Transfer Case Fluid - Transfer Case: Service and Repair Standard Procedure - NV233 Transfer Case NV233 - Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case (Fig. 70). 1. Raise vehicle. 2. Position drain pan under transfer case. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 41 - 54 Nm (30 - 40 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar ATF +4, type 9602, Automatic Transmission fluid. 7. Install and tighten fill plug to 41 - 54 Nm (30 - 40 ft. lbs.). 8. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Standard Procedure - NV233 Transfer Case > Page 4185 Fluid - Transfer Case: Service and Repair Standard Procedure - NV244 Transfer Case NV244 - Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case (Fig. 77). 1. Raise vehicle. 2. Position drain pan under transfer case. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 41 - 54 Nm (30 - 40 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar ATF +4, type 9602, Automatic Transmission fluid. 7. Install and tighten fill plug to 41 - 54 Nm (30 - 40 ft. lbs.). 8. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4189 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4190 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4194 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4197 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4198 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4199 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 4203 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4206 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4207 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4208 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4213 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4214 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4219 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4220 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4221 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4222 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4223 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 Seals and Gaskets: Service and Repair NV233 Front Output Shaft Seal NV133 - Transfer Case FRONT OUTPUT SHAFT SEAL / REMOVAL 1. Raise vehicle. 2. Remove front propeller shaft. 3. Remove front output shaft companion flange. 4. Remove seal from front case with suitable pry tool (Fig. 71). INSTALLATION 1. Install new front output seal in front case with Installer Tool 8143-A as follows: a. Place new seal on tool. Garter spring on seal goes toward interior of case. b. Start seal in bore with light taps from hammer (Fig. 72). Once seal is started, continue tapping seal into bore until installer tool seats against case. 2. Install the front output shaft companion flange. Tighten the flange nut to 122 - 176 Nm (90 - 130 ft. lbs.). 3. Install the front propeller shaft. Rear Retainer Bushing and Seal NV233 - Transfer Case Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 > Page 4228 REAR RETAINER BUSHING AND SEAL / REMOVAL 1. Raise vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal. 4. Using Remover 8158, remove the bushing from rear retainer (Fig. 74). INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer. 3. Using Installer 8157, drive bushing into retainer until installer seats against case (Fig. 75). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 > Page 4229 4. Using Installer D- 163, install seal in rear retainer (Fig. 76). 5. Install the rear propeller shaft. 6. Verify proper fluid level. 7. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 > Page 4230 Seals and Gaskets: Service and Repair NV244 Front Output Shaft Seal NV244 - Transfer Case FRONT OUTPUT SHAFT SEAL / REMOVAL 1. Raise vehicle. 2. Remove front propeller shaft. 3. Remove front output shaft companion flange. 4. Remove seal from front case with suitable pry tool (Fig. 78). INSTALLATION 1. Install new front output seal in front case with Installer Tool 8143-A as follows: a. Place new seal on tool. Garter spring on seal goes toward interior of case. b. Start seal in bore with light taps from hammer (Fig. 79). Once seal is started, continue tapping seal into bore until installer tool seats against case. 2. Install the front output shaft companion flange. Tighten the flange nut to 122 - 176 Nm (90 - 130 ft. lbs.). 3. Install the front propeller shaft. Rear Retainer Bushing and Seal NV244 - Transfer Case REAR RETAINER BUSHING AND SEAL / REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 > Page 4231 1. Raise vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal. 4. Using Remover 8158, remove the bushing from rear retainer (Fig. 81). INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer. 3. Using Installer 8157, drive bushing into retainer until installer seats against case (Fig. 82). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV233 > Page 4232 4. Using Installer D- 163, install seal in rear retainer (Fig. 83). 5. Install the rear propeller shaft. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4237 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4240 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4241 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4242 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 4246 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4249 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4250 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4251 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations > Page 4258 Transfer Case Shift Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Shift Motor: Description and Operation NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 78) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case > Page 4261 Transfer Case Shift Motor: Description and Operation NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 85) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case Transfer Case Shift Motor: Service and Repair NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 79) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 80) 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 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4264 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to .........122 - 176 Nm (90 -130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4265 Transfer Case Shift Motor: Service and Repair NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 86) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 87) 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 Lock & Seal or Loctite(tm) 242 to replenish Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4266 the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mount > Component Information > Specifications > NV233 Transfer Case Mount: Specifications Nut, Mounting 20 - 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mount > Component Information > Specifications > NV233 > Page 4271 Transfer Case Mount: Specifications Nut, Mounting 20 - 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation Solenoid Switch Valve / 45RFE - Automatic Transmission DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4287 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4288 Shift Solenoid: Description and Operation TRANSMISSION SOLENOID/ TRS ASSEMBLY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 116). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION - SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES 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 chart: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4289 L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4290 Shift Solenoid: Service and Repair Transmission Solenoid/TRS Assembly / 45RFE - Automatic Transmission REMOVAL 1. Remove the valve body from the transmission (Fig. 117). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 118). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Locations > Page 4298 Transfer Case Shift Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Shift Motor: Description and Operation NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 78) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Description and Operation > NV233 Transfer Case > Page 4301 Transfer Case Shift Motor: Description and Operation NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / DESCRIPTION The shift motor (Fig. 85) 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 72°F with 10 volts at the motor leads. 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case Transfer Case Shift Motor: Service and Repair NV233 Transfer Case NV233 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 79) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 80) 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 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4304 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to .........122 - 176 Nm (90 -130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4305 Transfer Case Shift Motor: Service and Repair NV244 Transfer Case NV244 - Transfer Case SHIFT MOTOR / 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 front output shaft companion flange from the transfer case. 5. Remove the bolts (Fig. 86) holding the shift motor and mode sensor assembly onto the transfer case. 6. Separate the shift motor and mode sensor assembly from the transfer case. INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts (Fig. 87) 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 Lock & Seal or Loctite(tm) 242 to replenish Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Shift Motor <--> [Transfer Case Actuator] > Component Information > Service and Repair > NV233 Transfer Case > Page 4306 the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the transfer case front output shaft companion flange onto the transfer case. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.). 6. Install the front propeller shaft. 7. Refill the transfer case as necessary. 8. Lower vehicle and verify transfer case operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 4312 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 4313 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 4317 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4322 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 4323 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Locations Transmission Control Module: Locations Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Transmission Control Module (4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 Transmission Control Module (TCM) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4349 Transmission Control Module: Description and Operation TRANSMISSION CONTROL MODULE Fig.12 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right side and is mounted to the radiator core support (Fig. 12). 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 hardwired 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+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB III 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) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4350 - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB III 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) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.13 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 13). Gear ratios can be determined by using the DRB III 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4351 Clutch Volumes 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 Clutch Volume chart identifies the appropriate clutch volumes and when they are monitored/updated. Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4352 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4353 Transmission Control Module: Service and Repair STANDARD PROCEDURE - TRANSAXLE QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4357 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4358 Transmission Control System Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4359 Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4360 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY - 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4365 Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4366 Control Module: Description and Operation TRANSFER CASE CONTROL MODULE Fig.14 Transfer Case Control Module (TCCM) The Transfer Case Control Module (TCCM) (Fig. 14) is a microprocessor-based assembly, controlling 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 PCI serial bus. Inputs include user selectable 4X4 modes that include AWD (NV244), 2WD (NV133 and NV233), 4HI, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the center section of the lower instrument panel, to the right of the steering column. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 PCI 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 PCI traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects PCI 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 TCCM 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 TCCM will solidly illuminate the source position's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4367 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 TCCM. - Proper transmit/receive messages are occurring on the PCI 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 PCI 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 TCCM. 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 PCI 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 TCCM. 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 PCI 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 TCCM. Shift Sequences Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM 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 TCCM strategy for handling blocked shifts will be described later. The process the TCCM 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 TCCM 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4368 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 TCCM 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 the Section on 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 TCCM 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 TCCM 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 TCCM 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 TCCM 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 TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM 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 TCCM 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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4369 - 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. NOTE: Static Shift Motor Braking is independent of ignition key position. Shift Attempt Limit To protect the transfer case system, the TCCM 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4375 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4376 Fluid Pressure Sensor/Switch: Description and Operation 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / 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, mounted on the side of the solenoid and 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 sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid 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. 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 and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4377 Pressure Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4378 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 82). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4382 Overdrive Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4383 Overdrive Switch: Description and Operation 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 96). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4384 Overdrive Switch: Service and Repair 45RFE - AUTOMATIC TRANSMISSION OVERDRIVE SWITCH / REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 97). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 98) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4385 2. Install the overdrive off switch into the connector (Fig. 99) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Transmission Mode Switch: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 251) 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 JTEC engine controller. OPERATION As the switch moves through its linear motion (Fig. 252) contacts slide across a circuit board which changes the resistance between the range sensing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4394 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4395 Transmission Mode Switch: Description and Operation 45RFE 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4396 Transmission Mode Switch: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 252) 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 JTEC engine controller. OPERATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 4397 As the switch moves through its linear motion (Fig. 253) 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 lames. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed Transmission Mode Switch: Testing and Inspection 42RE (A-500) 4 Speed 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4400 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4401 Transmission Mode Switch: Testing and Inspection 46RE 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 Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > 42RE (A-500) 4 Speed > Page 4402 rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return 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 Cluster Resistance Signal and the Cluster Signal Return 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 Fused Ignition Switch Output 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 Fused Ignition Switch Output 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed Transmission Mode Switch: Service and Repair 42RE (A-500) 4 Speed 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 (Fig. 253) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 254). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4405 7. Remove the TRS mounting bracket (Fig. 255) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 256), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4406 3. Install the TRS (Fig. 257) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 258). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4407 Transmission Mode Switch: Service and Repair 46RE 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 (Fig. 254) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 255). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4408 7. Remove the TRS mounting bracket (Fig. 256) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 257), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 4409 3. Install the TRS (Fig. 258) into the mounting bracket 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 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 259). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4413 Transmission Position Switch/Sensor: Description and Operation 45RFE - Automatic Transmission 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. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4414 Transmission Range Sensor Switch States Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4419 Transmission Speed Sensor: Specifications Bolt, Input Speed Sensor 105 in.lb Bolt, Output Speed Sensor 105 in.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4420 Transmission Speed Sensor: Specifications Sensor, Trans Speed 20 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4421 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4424 Transmission Speed Sensor: Description and Operation Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Input Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 81). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4427 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - AUTOMATIC TRANSMISSION Output Speed Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 95). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation 45RFE - Automatic Transmission Transmission Temperature Sensor / DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate inch Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: -^5GBattery (ambient) temperature Engine coolant temperature - In-gear run time since start-up Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4435 Transfer Case Selector Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV233 Transfer Case NV233 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 77) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4438 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 mashed 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4439 Four Wheel Drive Selector Switch: Description and Operation NV244 Transfer Case NV244 - Transfer Case SELECTOR SWITCH / DESCRIPTION The selector switch assembly (Fig. 84) is mounted in the vehicle 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 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 SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD/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/2WD and in-between positions, the TCCM may interpret the resistance as: - the AWD/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: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV233 Transfer Case > Page 4440 - 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Locations > Page 4444 Transfer Case Mode Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case Transfer Case Mode Sensor: Description and Operation NV233 Transfer Case NV233 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 73) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4447 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4448 Transfer Case Mode Sensor: Description and Operation NV244 Transfer Case NV244 - Transfer Case MODE SENSOR / DESCRIPTION The transfer case mode sensor (Fig. 80) 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 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. SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Transfer Case Mode Sensor <--> [Gear Sensor/Switch, Transfer Case] > Component Information > Description and Operation > NV233 Transfer Case > Page 4449 MODE SENSOR CHANNEL STATES 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4455 ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Anti-lock Brake .................................................................................................................................... ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4456 ABS Light: Description and Operation ABS INDICATOR An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) 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 ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-ON Message - Each time the cluster receives a lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp- OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the CAB for three consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the CAB will store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Antilock Brake Mounting Screws ............................................................................................................................................ 6 Nm (53 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 EBC 125 (RWAL) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 > Page 4465 EBC 325 (ABS) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions Controller Antilock Brake: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Controller Antilock Brake: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Controller Antilock Brake: Connector Views Controller Antilock Brake C2 Controller Antilock Brake C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Controller Antilock Brake: Electrical Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 4487 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKE Fig.3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig.4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.To program the CAB refer to the Chassis Diagnostic. System self-test When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 4488 The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the vehicle by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System REMOVAL NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Disconnect battery negative cable. (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB. (4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle. INSTALLATION NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs.). (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.) (4) Connect battery. (5) Bleed brake system Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4491 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Disconnect battery negative cable. Fig.5 Harness Connector Locks 2. Release the CAB harness connector locks, and remove the harness connectors from the CAB. Fig.6 Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4492 Fig.7 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 in. lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket Bolts 10 - 12 ft. lbs. ABS Assembly Mounting Nuts 102 inch lbs. ABS Assembly CAB Screws 36 - 42 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4496 Hydraulic Control Assembly - Antilock Brakes: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The Hydraulic Control Unit (HCU) consists of a valve body, pump, two accumulators and a motor. The assembly is mounted on the driver side inner fender under the hood. OPERATION The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4499 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock (RWAL) Valve RWAL VALVE DESCRIPTION The assembly is located on the drivers side inner fender under the hood. The assembly modulates hydraulic pressure to the rear brakes during an RWAL stop. OPERATION If the CAB senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any RWAL stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during a RWAL stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL assembly. The CAB will then reset the dump cycle counter in anticipation of the next RWAL stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and RWAL stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) REMOVAL 1. Disconnect battery negative cable. 2. Remove the brake lines from HCU. 3. Push the harness connector locks to release the locks, then remove the connectors from the CAB. 4. Remove the nuts which attaches the assembly to the mounting bracket. 5. Remove the assembly from the vehicle. INSTALLATION 1. Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs.). 2. Connect the CAB harnesses. 3. Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). 4. Connect battery. 5. Bleed brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 4502 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve Rwal Valve REMOVAL 1. Disconnect the RWAL assembly harness connector from the RWAL assembly. 2. Remove the brake lines from the assembly. 3. Remove the assembly mounting bolt and remove the assembly from the vehicle. INSTALLATION 1. Position the assembly on the inner fender well and install the mounting bolt. Tighten the mounting bolt to 20 - 27 Nm (15 - 20 ft. lbs.). 2. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 3. Install the RWAL assembly harness connector into the RWAL assembly. 4. Bleed base brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 inch lbs. Wheel Speed Sensors Rear Sensor Bolt 200 inch lbs. Rear Wheel Speed Sensor Mounting Bolt 200 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4508 Wheel Speed Sensor: Connector Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4509 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4512 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or signwave) is interpreted by the CAB. It then compares the frequency of the signwave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be ^ Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4513 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring Wheel Speed Sensor: Service and Repair Exciter Ring REMOVAL - EXCITER RING The exciter ring is mounted on the differential case. If the ring is damaged Refer to TONE RING REMOVAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4516 Wheel Speed Sensor: Service and Repair Front REMOVAL CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4517 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4518 Wheel Speed Sensor: Service and Repair Tone Wheel REMOVAL - TONE WHEEL The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation PEDAL DESCRIPTION A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot bolt and bushings. The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are all serviceable components. OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which move the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 4522 Brake Pedal Assy: Service and Repair REMOVAL 1. Remove stop lamp switch. 2. Remove clip securing booster push rod to brake pedal. 3. Remove pedal pivot pin C-clip and slide pin out of support bracket and pedal. 4. Remove pedal and bushings. INSTALLATION 1. Replace bushings if worn or damaged. 2. Lubricate pedal bushings and pivot pin with Mopar multi mileage grease, Lubriplate, or a silicone grease. 3. Install bushings in pedal and position pedal in support. 4. Insert pivot pin through support and pedal bushings and install C-clip. 5. Install booster push rod on brake pedal and install push rod retainer clip. 6. Install stop lamp switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4526 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Brake Warning ..................................................................................................................................... ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4527 Brake Warning Indicator: Description and Operation DESCRIPTION A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. OPERATION The red warning light alerts the driver if a pressure differential exists between the front and rear hydraulic systems or the parking brakes are applied. The lamp is turned on momentarily when the ignition switch is turn to the on position. This is a self test to verify the lamp is operational. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Disc Brake Caliper Bore 2.75 inch Caliper Mounting Pins 22 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4532 Brake Caliper: Description and Operation DESCRIPTION The calipers are a single piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake shoes do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. Fig. 2 Piston Seal Function During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake shoe. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4533 Brake Caliper: Service and Repair REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. 6. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged . 7. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 8. Remove caliper and brake shoes from caliper. DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. Piston Dust Boot 2. Remove piston dust boot. Use screw driver to push boot out of Groove. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4534 3. Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Caliper Piston Seal 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4535 INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid. 2. Lubricate caliper bushings and interior of bushing boots with silicone grease. Bushings And Boots Installation 3. Install bushing boots in caliper, then insert bushing into boot and push bushing into place. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4536 Seal Installation 4. Install new piston seal into seal groove with finger. Piston And Dust Boot 5. Install new dust boot on caliper piston and seat boot in piston groove. Caliper Piston Installation 6. Press piston into caliper bore by hand, use a turn and push motion to work piston into seal. 7. Press caliper piston to bottom of bore. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4537 Piston Dust Boot Installation 8. Seat dust boot in caliper with Installer Tool C-4842 and Tool Handle C-4171. 9. Replace caliper bleed screw if removed. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4538 4. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 6. Bleed base brake system. 7. Install wheel and tire assemblies. 8. Remove supports and lower vehicle. 9. Pump brake pedal to seat brake shoes. 10. Fill brake fluid reservoir. 11. Verify firm pedal before moving vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Riveted brake pads should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4542 Brake Pad: Service and Repair BRAKE PADS/SHOES REMOVAL 1. Clean the master cylinder reservoir and the filler caps. 2. Remove the reservoir filler cap and drain approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the fluid. 3. Raise and support the vehicle. 4. Remove the front wheel and tire assemblies. 5. Bottom the caliper pistons in the bores with a large C-clamp. Position the clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe. 6. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 7. Remove the caliper slide pins. 8. Remove the caliper and brake shoes. 9. Remove the outboard brake shoe. Pry one end of shoe retainer spring away from the caliper, Then tilt the shoe upward and rotate it out of the caliper. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4543 Inboard Brake Shoe 10. Remove the inboard shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston. 11. Support the caliper. Do not allow brake hose to support caliper weight. INSTALLATION 1. Clean slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with a thin coat of high temperature grease. 2. Install new slide pin bushings if necessary. 3. Install inboard shoe. Be sure retainer spring is firmly seated in caliper piston. 4. Insert outboard brake shoe in caliper. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4544 5. Insure the outboard shoe retainer spring are seated in the caliper. 6. Install caliper and brake shoes over rotor and into adapter. 7. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. 8. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 9. Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4545 10. Remove support and lower vehicle. 11. Pump brake pedal to seat brake shoes. 12. Fill brake fluid reservoir. 13. Verify a firm brake pedal before moving vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Rotor Specifications Rotor Specifications DISC BRAKE ROTOR TYPE Ventilated ROTOR DIAMETER 287 mm (11.3 in.) STANDARD ROTOR THICKNESS 24 mm (0.945 in.) MINIMUM ROTOR THICKNESS 22.6 mm (0.889 in.) ROTOR THICKNESS VARIATION (MAX) 0.013 mm (0.0005 in.) ROTOR RUNOUT (MAX) 0.102 mm (0.004 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4549 Brake Rotor/Disc: Testing and Inspection DIAGNOSIS AND TESTING - DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are light. Replace the rotor under the following conditions: severely scored - tapered - hard spots - cracked - below minimum thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake pad contact surface. Replace the rotor if worn below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339. Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake pads. Position the dial indicator plunger approximately 25.4 mm (1 inch) inward from the rotor edge. Maximum allowable rotor runout is 0.102 mm (0.004 inch). ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4550 Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 25.4 mm (1 inch) from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.013 mm (0.0005 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation Brake Rotor/Disc: Service and Repair Brake Rotor - Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper. 4. Remove retainers on wheel studs and remove rotor. INSTALLATION 1. Install rotor hub and install retainers. 2. Install brake caliper. 3. Install wheel and tire assembly. 4. Remove support and lower vehicle. 5. Depress brake pedal several time to seat brake shoes. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4553 Brake Rotor/Disc: Service and Repair Brake Rotor Machining STANDARD PROCEDURE - DISC ROTOR MACHINING The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the lathe. Equipment capable of machining only one side at a time may produce a tapered rotor. NOTE: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles hub/bearing. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Support Plate Mounting Bolts/Nuts 47 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4558 Backing Plate: Service and Repair SUPPORT PLATE REMOVAL 1. Remove wheel and tire assembly and brake drum. 2. Remove the brake shoe assembly. 3. Remove the parking brake cable from the parking brake lever. 4. Compress the parking brake cable retainer tabs. Then push the retainer and the cable through and out of the support plate. 5. Disconnect the brake line at the wheel cylinder. 6. Remove the wheel cylinder from the support plate. 7. Remove the axle shaft. 8. Remove the bolts attaching the support plate to the axle and remove the support plate. INSTALLATION 1. Apply bead of silicone sealer around axle mounting surface of support plate. 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel cylinder. 5. Install parking brake cable in support plate. 6. Install axle shaft. 7. Connect parking brake cable to lever on secondary shoe and install brake shoes on support plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake drum and wheel and tire assembly. 10. Bleed brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake Drum Specs Brake Drum Specs Drum Brake Size 228.6 x 63.5 mm (9 x 2.5 in.) 279 x 57 mm (11 x 2.25 in.) Drum Diameter (MAX) Cast/stamped into outside surface of drum This marking includes 0.76 mm (0.030 inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing. Diameter Variation (MAX) 0.076 mm (0.003 in.) Drum Runout (on lathe) 0.20 mm (0.008 in.) Initial Drum Machining Cuts 0.12 - 0.20 mm (0.005 - 0.008 in.) Initial machining cuts should be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as heavier feed rates can produce taper and surface variation. Finish Drum Machining Cuts 0.025 - 0.038 mm (0.001 - 0.0015 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4562 Brake Drum: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE DRUM The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Generally, a drum can be machined to a maximum of 1.52 mm (0.060 inch) oversize. Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum. BRAKE DRUM RUNOUT Measure drum diameter and runout with an accurate gauge. The most accurate method of measurement involves mounting the drum in a brake lathe and checking variation and runout with a dial indicator. Variations in drum diameter should not exceed 0.076 mm (0.003 inch). Drum runout should not exceed 0.20 mm (0.008 inch) out of round. Machine the drum if runout or variation exceed these values. Replace the drum if machining causes the drum to exceed the maximum allowable diameter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation Brake Drum: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove drum. If drum is difficult to remove, remove rear plug from access hole in support plate. Back-off self adjusting by inserting a thin screwdriver into access hole and push lever away from adjuster screw star wheel. Then insert an adjuster tool into brake adjusting hole rotate adjuster star wheel to retract brake shoes. 5. Vacuum brake components to remove brake lining dust. 6. Remove shoe return springs with brake spring Plier tool. 7. Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever. 8. Remove cable guide from secondary shoe and anchor plate from anchor pin. 9. Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. 10. Remove adjuster lever spring from pivot. 11. Disengage and remove shoe spring from brake shoes. 12. Disengage and remove adjuster screw assembly from brake shoes. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 4565 13. Remove brake shoe retainers, springs. 14. Remove secondary brake shoe from support plate. 15. Remove strut and spring. 16. Remove parking brake lever retaining clip from the secondary shoe and remove the lever. 17. Remove primary shoe from support plate. 18. Disengage parking brake lever from parking brake cable. CLEANING Clean the individual brake components, including the support plate and wheel cylinder exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. INSPECTION As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly. Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 4566 Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted. INSTALLATION 1. Clean and inspect individual brake components. 2. Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. 3. Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. 4. Install the parking brake cable to the parking brake lever. 5. Install parking brake lever to the secondary shoe and install retaining clip. 6. Install primary shoe on support plate. Secure shoe with new spring retainers and pin. 7. Install spring on parking brake strut and engage strut in primary. 8. Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. 9. Install anchor plate and adjuster cable eyelet on support plate anchor pin. 10. Install cable guide in secondary shoe and position cable in guide. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 4567 11. Assemble adjuster screw. Then install and adjuster screw between the brake shoes. CAUTION: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. 12. Install adjuster lever and spring and connect adjuster cable to lever. 13. Install secondary shoe retainers and spring. 14. Install shoe spring. Connect spring to secondary shoe first. Then to primary shoe. 15. Verify adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. 16. Adjust brake shoes to drum with brake gauge. 17. Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 4568 Brake Drum: Service and Repair Brake Drum Machining STANDARD PROCEDURE - BRAKE DRUM MACHINING The brake drums can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.12 - 0.20 mm (0.005 - 0.008 inch) at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.025 to 0.038 mm (0.001 to 0.0015 inch) are recommended and will generally provide the best surface finish. Be sure the drum is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks. The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge. CAUTION: Replace the drum if machining will cause the drum to exceed the maximum allowable diameter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4572 Brake Shoe: Adjustments ADJUSTMENTS - REAR DRUM BRAKE The rear drum brakes are equipped with a self-adjusting mechanism. Under normal circumstances, the only time adjustment is required is when the shoes are replaced, removed for access to other parts, or when one or both drums are replaced. Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. ADJUSTMENT WITH BRAKE GAUGE (1) Be sure parking brakes are fully released. (2) Raise rear of vehicle and remove wheels and brake drums. (3) Verify that left and right automatic adjuster levers and cables are properly connected. (4) Insert brake gauge in drum. Expand gauge until gauge inner legs contact drum braking surface. Then lock gauge in position. Adjusting Brake Shoes With Gauge (5) Reverse gauge and install it on brake shoes. Position gauge legs at shoe centers as shown. If gauge does not fit (too loose/too tight), adjust shoes. (6) Pull shoe adjuster lever away from adjuster screw star wheel. (7) Turn adjuster screw star wheel (by hand) to expand or retract brake shoes. Continue adjustment until gauge outside legs are light drag-fit on shoes. (8) Install brake drums and wheels and lower vehicle. (9) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8 - 10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. ADJUSTMENT WITH ADJUSTING TOOL (1) Be sure parking brake lever is fully released. (2) Raise vehicle so rear wheels can be rotated freely. (3) Remove plug from each access hole in brake support plates. (4) Loosen parking brake cable adjustment nut until there is slack in front cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4573 Fig. 6 Release type brake adjuster (5) Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel. (6) Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. (7) Push and hold adjuster lever away from star wheel with thin screwdriver. (8) Back off adjuster screw star wheel until brake drag is eliminated. (9) Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. (10) Install support plate access hole plugs. (11) Adjust parking brake cable and lower vehicle. (12) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8 - 10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation Brake Shoe: Service and Repair Removal and Installation REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove clip nuts securing brake drum to wheel studs. (4) Remove drum. If drum is difficult to remove, remove rear plug from access hole in support plate. Back-off self adjusting by inserting a thin screwdriver into access hole and push lever away from adjuster screw star wheel. Then insert an adjuster tool into brake adjusting hole rotate adjuster star wheel to retract brake shoes. (5) Vacuum brake components to remove brake lining dust. (6) Remove shoe return springs with brake spring plier tool. (7) Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever. (8) Remove cable guide from secondary shoe and anchor plate from anchor pin. (9) Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. (10) Remove adjuster lever spring from pivot. (11) Disengage and remove shoe spring from brake shoes. (12) Disengage and remove adjuster screw assembly from brake shoes. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 4576 (13) Remove brake shoe retainers, springs. (14) Remove secondary brake shoe from support plate. (15) Remove strut and spring. (16) Remove parking brake lever retaining clip from the secondary shoe and remove the lever. (17) Remove primary shoe from support plate. (18) Disengage parking brake lever from parking brake cable. INSTALLATION (1) Clean and inspect individual brake components. (2) Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. (3) Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. (4) Install the parking brake cable to the parking brake lever. (5) Install parking brake lever to the secondary shoe and install retaining clip. (6) Install primary shoe on support plate. Secure shoe with new spring retainers and pin. (7) Install spring on parking brake strut and engage strut in primary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 4577 (8) Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. (9) Install anchor plate and adjuster cable eyelet on support plate anchor pin. (10) Install cable guide in secondary shoe and position cable in guide. (11) Assemble adjuster screw. Then install and adjuster screw between the brake shoes. CAUTION: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. (12) Install adjuster lever and spring and connect adjuster cable to lever. (13) Install secondary shoe retainers and spring. (14) Install shoe spring. Connect spring to secondary shoe first. Then to primary shoe. (15) Verify adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. (16) Adjust brake shoes to drum with brake gauge. (17) Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 4578 Brake Shoe: Service and Repair Cleaning and Inspection CLEANING Clean the individual brake components, including the support plate and wheel cylinder exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. INSPECTION As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly. Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Over-heating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair WHEEL CYLINDERS REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 4582 7. Bleed base brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Disc Brake Caliper Bore 2.75 inch Caliper Mounting Pins 22 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4587 Brake Caliper: Description and Operation DESCRIPTION The calipers are a single piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake shoes do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. Fig. 2 Piston Seal Function During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake shoe. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4588 Brake Caliper: Service and Repair REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. 6. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged . 7. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 8. Remove caliper and brake shoes from caliper. DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. Piston Dust Boot 2. Remove piston dust boot. Use screw driver to push boot out of Groove. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4589 3. Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Caliper Piston Seal 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4590 INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid. 2. Lubricate caliper bushings and interior of bushing boots with silicone grease. Bushings And Boots Installation 3. Install bushing boots in caliper, then insert bushing into boot and push bushing into place. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4591 Seal Installation 4. Install new piston seal into seal groove with finger. Piston And Dust Boot 5. Install new dust boot on caliper piston and seat boot in piston groove. Caliper Piston Installation 6. Press piston into caliper bore by hand, use a turn and push motion to work piston into seal. 7. Press caliper piston to bottom of bore. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4592 Piston Dust Boot Installation 8. Seat dust boot in caliper with Installer Tool C-4842 and Tool Handle C-4171. 9. Replace caliper bleed screw if removed. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4593 4. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 6. Bleed base brake system. 7. Install wheel and tire assemblies. 8. Remove supports and lower vehicle. 9. Pump brake pedal to seat brake shoes. 10. Fill brake fluid reservoir. 11. Verify firm pedal before moving vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the Full mark on the brake fluid reservoir. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 4598 Brake Fluid: Fluid Type Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4599 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4600 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 an 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4601 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4605 Brake Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line Fittings Master Cylinder 170 inch lbs. Brake Line Fittings Wheel Cylinder 145 inch lbs. Brake Hose Front Fitting 145 inch lbs. Brake Hose Front Bolt 250 inch lbs. Brake Hose Rear Fitting 170 inch lbs. ABS Assembly Brake Line Fittings 170 inch lbs. RWAL Valve Brake Line Fittings 170 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4612 Brake Hose/Line: Description and Operation DESCRIPTION Flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled steel tubing is used to connect the master cylinder to the major hydraulic braking components and then to the flexible rubber hoses. Double inverted style and ISO style flares are used on the brake lines. OPERATION The hoses and lines transmit the brake fluid hydraulic pressure to the calipers and or wheel cylinders. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4613 Brake Hose/Line: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions. Also check brake hose installation. Faulty installation can result in kinked, twisted hoses, or contact with the wheels and tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure. The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks, leaks, or other damage. Heavily corroded lines will eventually rust through causing leaks. In any case, corroded or damaged brake lines should be replaced. Factory replacement brake lines and hoses are recommended to ensure quality, correct length and superior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs. Also remember that right and left brake hoses are not interchangeable. Use new copper seal washers at all caliper connections. Be sure brake line connections are properly made (not cross threaded) and tightened to recommended torque. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring Brake Hose/Line: Service and Repair Double Inverted Flaring STANDARD PROCEDURE - DOUBLE INVERTED FLARING A performed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. Inverted Flare And ISO Flare Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring > Page 4616 Cutting And Flaring Of Brake Fluid Tubing 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring > Page 4617 Brake Hose/Line: Service and Repair ISO Flaring STANDARD PROCEDURE - ISO FLARING A performed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare. Inverted Flare And ISO Flare To make a ISO flare use an ISO Flaring Tool Kit. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring > Page 4618 4. Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on the tube. 5. Install the correct size adapter on the flaring tool yoke screw. 6. Lubricate the adapter. 7. Align the adapter and yoke screw over the tube. 8. Turn the yoke screw in until the adapter is squarely seated on the tool bar. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation DESCRIPTION The combination valve contains a pressure differential valve and switch and a rear brake proportioning valve. The valve is not repairable and must be replaced as an assembly if diagnosis indicates this is necessary. OPERATION Pressure Differential Valve The pressure differential switch is connected to the brake warning light. The switch is actuated by movement of the switch valve. The switch monitors fluid pressure in the separate front/rear brake hydraulic circuits. A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle to the low pressure side. Movement of the valve pushes the switch plunger upward. This action closes the switch internal contacts completing the electrical circuit to the red warning light. The switch valve will remain in an actuated position until repairs to the brake system are made. Proportioning Valve The proportioning valve is used to balance front-rear brake action at high decelerations. The valve allows normal fluid flow during moderate braking. The valve only controls fluid flow during high decelerations brake stops. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4622 Brake Proportioning/Combination Valve: Testing and Inspection DIAGNOSIS AND TESTING - COMBINATION VALVE Pressure Differential Switch (1) Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. (2) Raise vehicle on hoist. (3) Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid. (4) Have helper press and hold brake pedal to floor and observe warning light. (a) If warning light illuminates, switch is operating correctly. (b) If light fails to illuminate, check circuit fuse, bulb, and wiring. The parking brake switch can be used to aid in identifying whether or not the brake light bulb and fuse is functional. Repair or replace parts as necessary and test differential pressure switch operation again. (5) If warning light still does not illuminate, switch is faulty. Replace combination valve assembly, bleed brake system and verify proper switch and valve operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4623 Brake Proportioning/Combination Valve: Service and Repair REMOVAL (1) Disconnect wire from the pressure differential switch. (2) Disconnect rear brake lines from combination valve. (3) Remove the bolt from the combination valve and remove the valve. INSTALLATION (1) Install the combination valve to the bracket and tighten the mounting bolt to 20 - 27 Nm (15 - 20 ft. lbs.). If vehicle is equipped with ABS brakes tighten the bolt to 10 - 13 Nm (7 - 10 ft. lbs.). (2) Install the brake lines to the combination valve. (3) Tighten the brake line to 19 Nm (170 inch lbs.). (4) Connect the wire to the pressure differential switch. (5) Bleed brakes system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket Bolts 10 - 12 ft. lbs. ABS Assembly Mounting Nuts 102 inch lbs. ABS Assembly CAB Screws 36 - 42 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4627 Hydraulic Control Assembly - Antilock Brakes: Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The Hydraulic Control Unit (HCU) consists of a valve body, pump, two accumulators and a motor. The assembly is mounted on the driver side inner fender under the hood. OPERATION The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4630 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock (RWAL) Valve RWAL VALVE DESCRIPTION The assembly is located on the drivers side inner fender under the hood. The assembly modulates hydraulic pressure to the rear brakes during an RWAL stop. OPERATION If the CAB senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any RWAL stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during a RWAL stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL assembly. The CAB will then reset the dump cycle counter in anticipation of the next RWAL stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and RWAL stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) REMOVAL 1. Disconnect battery negative cable. 2. Remove the brake lines from HCU. 3. Push the harness connector locks to release the locks, then remove the connectors from the CAB. 4. Remove the nuts which attaches the assembly to the mounting bracket. 5. Remove the assembly from the vehicle. INSTALLATION 1. Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs.). 2. Connect the CAB harnesses. 3. Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). 4. Connect battery. 5. Bleed brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 4633 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve Rwal Valve REMOVAL 1. Disconnect the RWAL assembly harness connector from the RWAL assembly. 2. Remove the brake lines from the assembly. 3. Remove the assembly mounting bolt and remove the assembly from the vehicle. INSTALLATION 1. Position the assembly on the inner fender well and install the mounting bolt. Tighten the mounting bolt to 20 - 27 Nm (15 - 20 ft. lbs.). 2. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 3. Install the RWAL assembly harness connector into the RWAL assembly. 4. Bleed base brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 160 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4637 Brake Master Cylinder: Description and Operation DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4638 Brake Master Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge to booster check valve with short length of hose and T-fitting. 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp hose shut between vacuum source and check valve. 5. Stop engine and observe vacuum gauge. 6. If vacuum drops more than one inch HO (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve. 2. Remove check valve and valve seal from booster. 3. Use a hand operated vacuum pump for test. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4639 4. Apply 15-20 inches vacuum at large end of check valve. 5. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise. Master Cylinder Bleeding - Typical (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir. (3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4642 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation REMOVAL Master Cylinder 1. Remove brake lines from the master cylinder. 2. Disconnect the low fluid level switch. 3. Remove mounting nuts from the master cylinder. 4. Remove master cylinder. INSTALLATION NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install master cylinder on booster mounting studs. 2. Install mounting nuts and tighten to 18 Nm (160 inch lbs.). 3. Install brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the low fluid level switch connector. 5. Fill and bleed base brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4643 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation FLUID RESERVOIR REMOVAL 1. Remove reservoir cap and empty fluid into drain container. 2. Clamp cylinder body in vise with brass protective jaws. Brake Fluid Reservoir Retaining Pins 3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins . 4. Loosen reservoir from grommets with pry tool. Brake Fluid Reservoir Removal 5. Remove reservoir by rocking it to one side and pulling free of grommets. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4644 Grommet Removal 6. Remove old grommets from cylinder body. INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. Brake Fluid Reservoir Grommet Installation 1. Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. 2. Start reservoir in grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets. 3. Install pins that retain reservoir to cylinder body. 4. Fill and bleed master cylinder on bench before installation in vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair WHEEL CYLINDERS REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 4648 7. Bleed base brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable REMOVAL - FRONT PARK BRAKE CABLE 1. Raise and support the vehicle. 2. Loosen cable adjusting nut. 3. Disengage front cable from cable tensioner. 4. Remove support cable from the front cable. 5. Remove support and lower vehicle. 6. Remove left kick panel. 7. Fold left front edge of floor covering rearward and remove cable grommet from floor pan. 8. Remove cable from park brake pedal assembly. 9. Work cable and housing assembly up through floor pan. 10. Remove front cable from vehicle. INSTALLATION - FRONT PARK BRAKE CABLE 1. Insert front cable through floor pan and install grommet. 2. Insert cable retainer into hole at bottom of pedal assembly bracket and connect cable end. 3. Fold floor covering down and install kick panel. 4. Raise and support vehicle. 5. Install support cable to the front cable. 6. Attach front cable to tensioner. 7. Adjust parking brakes. 8. Remove support and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4654 Parking Brake Cable: Service and Repair Rear Parking Brake Cable REMOVAL - REAR PARK BRAKE CABLES 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Loosen tensioner adjuster nut. 4. Remove the right cable from the extension cable. 5. Remove the right cable from the frame clip and pull the cable housing through the left cable connector. 6. Remove the left cable connector from the left cable. 7. Pull both cables through the cable bracket. 8. Remove the right cable mounting retainers from the from the differential housing. 9. Remove the brake drums. 10. Disconnect each cable from park brake lever. 11. Compress tabs on each cable housing retainer at the brake support plate. 12. Remove the cables from the brake support plates. INSTALLATION - REAR PARK BRAKE CABLES 1. Push each cable housing through the brake support plate hole until cable housing retainer tabs lock into place. NOTE: Pull on the cable housing to ensure it is lock into place. 2. Pull back on the end of the cable. Then push the cable in to engage the cable in the park brake lever. NOTE: Pull on the cable end to ensure it is attached it the park brake lever. 3. Install the brake drums. 4. Install right cable mounting retainers. 5. Push the cables housing through the cable bracket 6. Install the left cable onto the cable connector. 7. Push the right cable housing through the left cable connector and connect the cable to the extension cable. 8. Install the wheel and tire assemblies. 9. Perform park brake adjustment procedure. 10. Remove support and lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair RELEASE REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back side of the park brake release handle. 3. Disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. Park Brake Release Handle Remove/Install 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry one of the park brake handle hinge tabs away from its pivot pin on the instrument panel. 5. While prying the park brake release handle hinge tab with one hand, use the other hand to pull the handle firmly down and away from the pivot pin. 6. Remove the park brake release handle from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the park brake release handle to the instrument panel. 2. Engage one of the park brake release handle hinge tabs with one of the pivot pins on the instrument panel. 3. Align the second park brake release handle hinge tab hinge over the second pivot pin on the instrument panel. 4. Press firmly on the park brake release handle over the second hinge tab until it snaps over the second pivot pin on the instrument panel. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back side of the park brake release handle over the linkage rod. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Description and Operation Parking Brake Pedal: Description and Operation DESCRIPTION The rear drum brake shoes serve as the parking brakes. The parking brakes are operated by a system of cables and levers attached to the rear brake secondary shoes. OPERATION The shoes make contact with the brake drum surface by a cable and lever mechanism attached to the secondary brake shoe. The front parking brake cable is connected to the parking brake pedal and to the rear cables. An intermediate cable is used on some vehicles to connect the front and rear cables. The parking brake pedal assembly is mounted on the driver side cowl panel. The front cable is directly attached to the assembly. The pedal assembly contains a spring loaded mechanism to hold the pedal in the applied position. A rod and spring are used to release the ratchet mechanism and return the pedal to normal position. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Description and Operation > Page 4661 Parking Brake Pedal: Service and Repair Pedal REMOVAL 1. Remove left side kick panel. 2. Remove brake release rod from pedal assembly. 3. Disconnect brake warning lamp switch. 4. Remove front parking brake cable. 5. Remove mounting nuts and mounting bolt. 6. Slide assembly rearward off the mounting studs. INSTALLATION 1. Install assembly on the mounting studs. 2. Install mounting bolt and nuts. 3. Install front parking brake cable. 4. Connect brake warning lamp switch. 5. Install brake release rod to pedal assembly. 6. Install left side kick panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments ADJUSTMENTS - PARK BRAKE CABLE TENSIONER NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise vehicle. 2. Back off cable tensioner adjusting nut at equalizer to create slack in cables. 3. Remove rear wheel/tire assemblies. Then remove brake drums. 4. Verify brakes are in good condition and operating properly. 5. Verify park brake cables operate freely and are not binding, or seized. 6. Check rear brake shoe adjustment with standard brake gauge. 7. Install drums and verify that drums rotate freely without drag. 8. Reinstall wheel/tire assemblies after brake shoe adjustment is complete. 9. Lower vehicle enough for access to park brake foot pedal. Then fully apply park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise vehicle again. 11. Mark tensioner rod 6.35 mm (1/4 inch) from edge of tensioner bracket. 12. Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower vehicle until rear wheels are 15 - 20 cm (6 - 8 inch) off shop floor. 14. Release park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Locations Parking Brake Warning Lamp: Locations The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Locations > Page 4668 Parking Brake Warning Lamp: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. The brake indicator consists of stencil-like cutouts of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) 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 brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-ON Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if a vehicle with an automatic transmission is not in Park or Neutral, or if the engine is running on vehicles with a manual transmission. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for three consecutive seconds, the brake indicator will be illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the CAB. Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper park brake status messages to the CAB. The CAB then sends the proper brake indicator lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). The park brake switch input to the CTM and the brake pressure switch input to the CAB may be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake Booster Type Tandem Diaphragm Brake Booster Mounting Nuts 250 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4673 Vacuum Brake Booster: Description and Operation POWER BRAKE BOOSTER DESCRIPTION All models use a tandem diaphragm, power brake booster. NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm. The outer edge of the diaphragm is secured to the housing. The booster push rod, which connects the booster to the brake pedal and master cylinder, is attached to the center of the diaphragm. A check valve is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4674 Vacuum Brake Booster: Testing and Inspection "For information regarding this component please refer to master cylinder testing and inspection" Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4675 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum lines at booster. 3. Remove clip securing booster push rod to brake pedal. 4. Remove nuts from booster mounting studs. 5. Remove booster, spacer and gaskets from front cowl panel. INSTALLATION 1. Position spacer and gaskets on booster studs. 2. Guide booster studs into cowl panel holes and seat booster on panel. 3. Install and tighten booster attaching nuts to 28 Nm (250 inch lbs.). 4. Install booster push rod on brake pedal and install clip. 5. Install booster check valve if removed and connect vacuum hose to check valve. 6. Install master cylinder. 7. Fill and bleed brake system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection POWER BOOSTER CHECK VALVE TEST (1) Disconnect vacuum hose from check valve. (2) Remove check valve and valve seal from booster. (3) Use a hand operated vacuum pump for test. (4) Apply 15 - 20 inches vacuum at large end of check valve. (5) Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Antilock Brake Mounting Screws ............................................................................................................................................ 6 Nm (53 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 EBC 125 (RWAL) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125 > Page 4685 EBC 325 (ABS) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions Controller Antilock Brake: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Controller Antilock Brake: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Controller Antilock Brake: Connector Views Controller Antilock Brake C2 Controller Antilock Brake C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Controller Antilock Brake: Electrical Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 4707 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKE Fig.3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig.4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.To program the CAB refer to the Chassis Diagnostic. System self-test When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Page 4708 The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the vehicle by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System REMOVAL NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Disconnect battery negative cable. (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB. (4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle. INSTALLATION NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. (1) Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs.). (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.) (4) Connect battery. (5) Bleed brake system Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4711 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Disconnect battery negative cable. Fig.5 Harness Connector Locks 2. Release the CAB harness connector locks, and remove the harness connectors from the CAB. Fig.6 Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4712 Fig.7 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CAB refer to the Chassis Diagnostic. 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 in. lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4717 Brake Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 inch lbs. Wheel Speed Sensors Rear Sensor Bolt 200 inch lbs. Rear Wheel Speed Sensor Mounting Bolt 200 inch lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4726 Wheel Speed Sensor: Connector Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4727 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4730 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or signwave) is interpreted by the CAB. It then compares the frequency of the signwave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be ^ Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4731 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring Wheel Speed Sensor: Service and Repair Exciter Ring REMOVAL - EXCITER RING The exciter ring is mounted on the differential case. If the ring is damaged Refer to TONE RING REMOVAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4734 Wheel Speed Sensor: Service and Repair Front REMOVAL CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4735 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Exciter Ring > Page 4736 Wheel Speed Sensor: Service and Repair Tone Wheel REMOVAL - TONE WHEEL The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4742 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4743 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4744 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4745 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Clutch Switch: Diagrams Clutch Interlock Switch Jumper (A/T) Clutch Interlock Switch (M/T) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 4749 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position switch is in the starter circuit. The switch is located on the clutch master cylinder push rod. OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 4750 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION SWITCH REMOVAL AND INSTALLATION Switch is not serviced separately. If switch replacement is necessary, replace clutch master cylinder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 4755 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Motor Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4763 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4764 Starter Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4765 Engine Starter Motor Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4766 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4767 Starter Relay: Testing and Inspection Fig.14 Starter Relay The starter relay (Fig. 14) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear- shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4768 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig.15 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 15). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 4773 Jump Starting: Service and Repair STANDARD PROCEDURE JUMP STARTING PROCEDURE WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary. - Frozen battery - Yellow or bright color test indicator, if equipped. - Low battery fluid level. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn OFF all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn OFF all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. Fig.7 Jumper Cable Clamp Connections 5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible. 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 4774 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 mm.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: Disconnect BLACK cable clamp from engine ground on disabled vehicle. - When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. - Disconnect RED cable clamp from battery positive terminal on disabled vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Cable Eyelet Nut at Solenoid Stud .............................................................................................................................................. 14 Nm (120 in. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 4778 Battery Cable: Description and Operation Fig.12 Battery Cables The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other components on some models. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber protective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 4779 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery p05itive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig.1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4783 Battery Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4784 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4785 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Batt (Out Of Calibration) - Ambient/Batt Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4786 Battery Temperature Sensor: Service and Repair REMOVAL Fig.1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray 2. Connect pigtail harness. 3. Install battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Turn the ignition switch to the OFF position. Be certain that all electrical accessories are turned OFF. 2. Loosen the battery negative cable terminal clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post. 4. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post. Fig.11 Battery Hold Downs Remove/Install 5. Remove the two hold down bolts that secure the hold down strap/battery thermal guard unit to the U-nuts in the battery tray. 6. Remove the hold down strap/battery thermal guard unit from the top of the battery case. INSTALLATION 1. Clean and inspect the battery hold down hardware. 2. Install the hold down strap/battery thermal guard unit over the top of the battery case. 3. Install and tighten the two hold down bolts that secure the hold down strap/battery thermal guard unit to the U-nuts in the battery tray Tighten the bolts to 2.1 Nm (19 in. lbs.). 4. Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in. lbs.). 5. Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in lbs). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4791 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the battery tray (Refer to BATTERY - REMOVAL). 2. Remove the Power Distribution Center (PDC) from the stanchions on the rear of the battery tray (Refer to POWER DISTRIBUTION CENTER - REMOVAL). Fig.18 Battery Tray Remove/Install 3. Remove the two screws that secure the inboard side of the battery tray to the battery tray support. 4. Remove the two screws that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel. 5. Remove the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. 6. Remove the battery temperature sensor from the battery tray. Refer to Battery Temperature Sensor in the Charging section for battery temperature sensor removal procedures. 7. Remove the battery tray from the battery tray support and the front extension of the left front wheelhouse inner panel. 8. Remove the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. 9. Remove the two screws that secure the front of the battery tray support to the left side of the radiator yoke. 10. Remove the battery tray support from the left front wheelhouse inner panel and the left side of the radiator yoke. INSTALLATION 1. Clean and inspect the battery tray Refer to Battery System for battery tray cleaning and inspection procedures. 2. Position the battery tray support onto the left front wheelhouse inner panel and the left side of the radiator yoke. 3. Install and tighten the two screws that secure the battery tray support to the left side of the radiator yoke. Tighten the screws to 11.3 Nm (100 in. lbs.). 4. Install and tighten the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. Tighten the screw to 11.3 Nm (100 in. lbs.). 5. Install the battery temperature sensor onto the battery tray. Refer to Battery Temperature Sensor in the Charging for the location of battery temperature sensor installation procedures. 6. Position the battery tray onto the battery tray support and the front extension of the left front wheelhouse inner panel. Be certain that the battery temperature sensor wiring is properly routed. 7. Install and tighten the two screws (rear screw first) that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel. Tighten the screws to 12.4 Nm (110 in. lbs.). 8. Install and tighten the two screws that secure the inboard side of the battery tray to the battery tray support. Tighten the screws to 12.4 Nm (110 in. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4792 lbs.). 9. Install and tighten the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. Tighten the screw to 12.4 Nm (110 in. lbs.). 10. Install the Power Distribution Center (PDC) onto the stanchions on the rear of the battery tray (Refer to POWER DISTRIBUTION CENTER INSTALLATION). 11. Install the battery onto the battery tray (Refer to BATTERY - INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Generator Ratings Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4798 Torque - Charging System Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4799 4.7L Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4800 Alternator: Service Precautions WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4801 Alternator: Description and Operation GENERATOR The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator battery terminal. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is use on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. Refer to Charging System for the charging system diagnostic procedures. Refer to Power Distribution for the location of complete PDC circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement Alternator: Service and Repair Generator Replacement REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. Refer to Cooling System for procedures. 3. Unsnap plastic cable protector cover from B+ mounting stud. Fig.4 Remove/Install Generator 4. For This Engine: Remove 3 generator mounting bolts (Fig. 4). Position generator for access to wire connectors. Fig.5 Generator Connectors - Typical Bosch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 4804 Fig.6 Generator Connectors - Typical Denso 5. Remove B+ terminal mounting nut at rear of generator (Fig. 5) or (Fig. 6). Disconnect terminal from generator. 6. Disconnect field wire connector at rear of generator by pushing on connector tab and pulling connector from generator. 7. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and snap field wire connector into rear of generator. 2. Install B+ terminal to generator mounting stud. Tighten mounting nut to 12 Nm (108 in. lbs.) torque. 3. Install generator mounting fasteners and tighten as follows: - Vertical mounting bolt For This engine- 55 Nm (40 ft. lbs.) - Long horizontal mounting bolt For This engine- 55 Nm (40 ft. lbs.) - Short horizontal mounting bolt For This engine- 74 Nm (55 ft. lbs.) CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. 4. Install generator drive belt. 5. Snap cable protector cover to B+ mounting stud. 6. Install negative battery cable to battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Replacement > Page 4805 Alternator: Service and Repair Generator Cartridge Fuse Replacement REMOVAL If a generator cartridge fuse fails, be certain to inspect and test the vehicle charging system before replacing the cartridge fuse and returning the vehicle to service. Refer to Charging System for the charging system diagnostic procedures. 1. Disconnect and isolate the battery negative cable. 2. Unlatch and remove the cover from the Power Distribution Center (PDC). 3. Remove the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. 4. Remove the generator cartridge fuse from the PDC. INSTALLATION If a generator cartridge fuse fails, be certain to inspect and test the vehicle charging system before replacing the cartridge fuse and returning the vehicle to service. Refer to Charging System for the charging system diagnostic procedures. 1. Position the generator cartridge fuse onto the two B(+) terminal stud bus bars within the PDC. 2. Install and tighten the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. Tighten the screws to 3.4 Nm (30 in. lbs.). Be certain that both screws are tightened to the proper torque value. 3. Install and latch the cover onto the PDC. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 4809 Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately If replacement is necessary the PCM must be replaced. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100 Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Clutch Switch: Diagrams Clutch Interlock Switch Jumper (A/T) Clutch Interlock Switch (M/T) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Page 4814 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position switch is in the starter circuit. The switch is located on the clutch master cylinder push rod. OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Page 4815 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION SWITCH REMOVAL AND INSTALLATION Switch is not serviced separately. If switch replacement is necessary, replace clutch master cylinder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection Ignition Switch Lock Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission and a floor mounted shifter: on certain models, a lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Testing and Inspection > Page 4820 Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER HOUSING REMOVAL The ignition key must be in the key cylinder 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 (Fig. 9) is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Manufacturer ....................................................................................................................................... .......................................................................... Denso Power Rating ................................................. ....................................................................................................................... 1.4 Kilowatt (1.9 Horsepower) Voltage ................................................................................................................................................ ...................................................................... 12 Volts Free Running Test Voltage .................................................................................................................. ...................................................................... 11 Volts Free Running Test Maximum Amperage Draw ................................................................................................................................................... 73 Amperes Free Running Test Minimum Speed .................................................................................................... .................................................................... 3601 rpm * Cranking Amperage Draw Test ............................................................................................................................................................. 125 - 250 Amperes * Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4828 Starter Motor: Mechanical Specifications Starter Motor and Solenoid (Part 1 Of 2) Starter Motor and Solenoid (Part 2 Of 2) Torque Starter Mounting Nuts/Bolts ................................................................................................................. ..................................................... 68 Nm (50 ft. lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4829 Starter Motor: Locations This automatic transmission starter motor is mounted with two bolts to the torque converter housing on the left side of the engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4830 Starter Motor: Description and Operation This engine's automatic transmission starter motor is mounted with two bolts to the torque converter housing on the left side of the engine. The starter motors for all of the remaining engine and transmission combinations are mounted with one bolt, a stud and a nut to the clutch or convertor housing, and are located on the left side of the engine. The electric motors of both starters have four brushes contacting the motor commutator. These engines starter motors feature four electromagnetic field coils wound around four pole shoes. The starter motors are serviced only as a unit with starter solenoids, and cannot be repaired. If either component is faulty or damaged, the entire starter motor and starter solenoid unit must be replaced. The starter motor is equipped with a gear reduction (intermediate transmission) system. The gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed, and delivers increased torque through the starter pinion gear to the starter ring gear. The starter motor is activated by an integral heavy duty starter solenoid switch mounted to the overrunning clutch housing. This electromechanics switch connects and disconnects the feed of battery voltage to the starter motor, and actuates a shift fork that engages and disengages the starter pinion gear with the starter ring gear. The starter motor uses an overrunning clutch and starter pinion gear unit to engage and drive the gears on the flywheel (or flywheel ring gear). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4831 Starter Motor: Testing and Inspection Correct starter motor operation can be confirmed by performing following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Starting Specifications for starter motor specifications. 1. Remove starter motor from vehicle. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect suitable volt-ampere tester and 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Starting Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Starting Specifications section for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4832 Starter Motor: Service and Repair REMOVAL Manual Transmission 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. Fig.12 Starter Motor Remove/Install - All 3.9L/5.9L Or 4.7L Engine With Man. Trans. 3. Remove nut securing starter motor to stud on transmission housing (Fig. 12). 4. While supporting starter motor, remove bolt securing starter motor to transmission housing. 5. If equipped with automatic transmission, slide transmission cooler tube bracket forward on tubes far enough for starter motor to be removed from lower mounting stud. 6. Lower starter motor from front transmission housing far enough to access and remove nut securing battery cable eyelet to starter solenoid stud. Always support starter motor during this process. Do not let starter motor hang from wire harness. 7. Remove solenoid wire solenoid terminal stud. 8. Disconnect battery cable solenoid wire from receptacle on starter solenoid. 9. Remove starter motor from transmission housing. Automatic Transmission 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4833 Fig.13 Starter Motor Remove/Install - 4.7L Engine With Automatic Transmission 3. Remove bolt and washer (rearward facing) securing starter motor to the transmission housing (Fig. 13). 4. While supporting starter motor, remove bolt and washer (rearward facing) securing starter motor to the transmission housing. 5. Lower starter motor from front of transmission housing far enough to access and remove nut securing battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Always support starter motor during this process. Do not let starter motor hang from wire harness. 6. Remove battery cable eyelet terminal from solenoid B(+) terminal stud. 7. Disconnect battery cable solenoid terminal wire harness connector from receptacle on starter solenoid. 8. Remove starter motor from transmission housing. INSTALLATION Manual Transmission 1. Position starter motor to transmission housing. 2. Connect battery cable solenoid terminal wire harness connector to connector receptacle on starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 3. Install battery cable eyelet terminal onto solenoid B(+) terminal stud. 4. Install and tighten nut securing battery cable eyelet terminal to starter solenoid B(+) terminal stud. Tighten nut to 13.6 Nm (120 in. lbs.). 5. Position starter motor over stud on transmission housing. 6. If equipped with automatic transmission, slide automatic transmission cooler tube bracket rearward on tubes and into position over starter motor flange. 7. Loosely install the washers, bolt, and nut to starter. Tighten bolt and nut to 67.8 Nm (50 ft. lbs.). 8. Lower vehicle. 9. Connect negative battery cable. Automatic Transmission 1. Position starter motor to transmission housing. 2. Connect battery cable solenoid terminal wire harness connector to connector receptacle on starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 3. Install battery cable eyelet terminal onto solenoid B(+) terminal stud. 4. Install and tighten nut securing battery cable eyelet terminal to starter solenoid B(+) terminal stud. Tighten nut to 13.6 Nm (120 in. lbs.). 5. Position starter motor to transmission housing and loosely install two bolts/washers. 6. Tighten bolts to 67.8 Nm (50 ft. lbs.). 7. Lower vehicle. 8. Connect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Motor Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4837 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4838 Starter Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4839 Engine Starter Motor Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4840 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4841 Starter Relay: Testing and Inspection Fig.14 Starter Relay The starter relay (Fig. 14) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear- shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4842 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig.15 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 15). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Electrical Specifications Starter Solenoid: Electrical Specifications Manufacturer ....................................................................................................................................... .......................................................................... Denso Power Rating ................................................. ....................................................................................................................... 1.4 Kilowatt (1.9 Horsepower) Voltage ................................................................................................................................................ ...................................................................... 12 Volts Free Running Test Voltage .................................................................................................................. ...................................................................... 11 Volts Free Running Test Maximum Amperage Draw ................................................................................................................................................... 73 Amperes Free Running Test Minimum Speed .................................................................................................... .................................................................... 3601 rpm Solenoid Closing Maximum Voltage Required ........................................................................................................................................................ 7.5 Volts * Cranking Amperage Draw Test ............................................................................................................................................................. 125 - 250 Amperes * Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Electrical Specifications > Page 4847 Starter Solenoid: Mechanical Specifications Starter Motor and Solenoid (Part 1 Of 2) Starter Motor and Solenoid (Part 2 Of 2) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 4848 Starter Solenoid: Testing and Inspection This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Disconnect wire from solenoid field coil terminal. Fig.8 Continuity Test - 3.9L/4.7L/5.9L Engine - Typical 3. Check for continuity between solenoid terminal and solenoid field coil terminal with continuity tester (Fig. 8). There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor assembly. Fig.10 Continuity Test - 3.9L/4.7L/5.9L Engine - Typical 4. Check for continuity between solenoid terminal and solenoid case (Fig. 10). There should be continuity If not OK, replace faulty starter motor assembly Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Auxiliary Power Outlet: Connector Views Center Power Outlet Cigar Lighter/Power Outlet Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 Auxiliary Power Outlet: Electrical Diagrams 8w-41-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 8w-41-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4874 Auxiliary Power Outlet: Service Precautions WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4875 Auxiliary Power Outlet: Description and Operation CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit, and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or On positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet Test WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 3.If not OK, repair the open fused ignition switch output (run/accessory) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity If OK, go to Step 4.If not OK, go to Step 5. 4. Turn the ignition switch to the ON position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6.If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test > Page 4878 Auxiliary Power Outlet: Testing and Inspection Power Outlet Test WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3.If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity If OK, go to Step 4.If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity If OK, go to Step 6.If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Outlet Replacement REMOVAL WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. Fig.2 Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base (Fig. 2). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4881 Fig.3 Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel (Fig. 3). 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4882 Auxiliary Power Outlet: Service and Repair Power Outlet REMOVAL WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. Fig.10 Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4883 Fig.11 Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel (Fig. 11). 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4884 Auxiliary Power Outlet: Service and Repair Rear Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams Circuit Breaker: Diagrams Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 4888 Circuit Breaker Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 4889 Circuit Breaker: Description and Operation Automatic resetting circuit breakers in the junction block are used to protect the power seat and power window system circuits. These circuit breakers can protect the systems from a short circuit, or overload condition caused by an obstructed or stuck seat adjuster, window glass or regulator. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 4890 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations Power Distribution Center (PDC): Component Locations Fig.8 Power Distribution Center Location - Typical The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4895 Power Distribution Center (PDC): Connector Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4896 Power Distribution Center (PDC): Fuse and Fusible Link Locations Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4897 Fuses (PDC) Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 Power Distribution Center (PDC): Diagrams C106 C106 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4900 C106 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4901 Power Distribution Center (PDC): Diagrams C107 C107 C107 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4902 Joint Connector No.1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4903 Joint Connector No.2 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4904 Joint Connector No.3 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4905 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION CENTER Fig.9 Power Distribution Center Location - Typical All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to 13 International Standards Organization (ISO) relays (one standard-type and 12 micro-type), two joint connectors (one 16-way and one 26-way) and a 16-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. All of the current from the battery and the generator output enters the PDC through one cable with eyelets that are secured with a nut to the one B(+) terminal stud located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Wiring for the location of complete PDC circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4906 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the Wiring Section for the location of more information on the headlamp and dash wire harness connector locations. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 5. Unlatch and remove the cover from the PDC. 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the B(+) terminal stud in the PDC and remove the eyelet from the stud. 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit off of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. Refer to Power Distribution for the location of complete PDC circuit diagrams and cavity assignments. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 13. Reconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness connector locations. 14. Reconnect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 4911 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4914 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4915 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4916 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4917 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4918 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4919 Fuse: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4920 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4923 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4924 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4925 Fuse: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4926 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 4931 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Fuse Block: Connector Views Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Junction Block C11 Junction Block C12 Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 Fuse Block: Electrical Diagrams 8w-12-6 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 8w-12-7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 8w-12-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 8w-12-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 8w-12-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 8w-12-11 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 8w-12-12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 8w-12-13 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 8w-12-14 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 8w-12-15 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 8w-12-16 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 8w-12-17 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 8w-12-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 8w-12-19 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 8w-12-20 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 8w-12-21 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 8w-12-22 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4975 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4978 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4979 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4980 Fuse Block: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4981 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4982 Fuse Block: Description and Operation JUNCTION BLOCK Fig.6 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 6). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4983 Fuse Block: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 7). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig.8 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 8). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4984 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 Joint Connector No. 1 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4989 Joint Connector No. 2 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4990 Joint Connector No. 3 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4991 Joint Connector No. 4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Fig.4 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 4) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4995 Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Junction Block (JB). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left on. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition - Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut OFF (time out). This may take up to 3 minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to 3 minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about 3 minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center ( PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4996 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4997 Ignition Off-Draw (IOD) Fuse: Service and Repair IOD FUSE REMOVAL Fig.5 Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5003 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5006 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5007 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5008 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5009 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5010 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5011 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5012 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5013 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5016 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5017 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5018 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5019 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5020 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5021 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5022 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5027 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5030 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5031 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5032 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5033 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5034 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5035 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5036 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5037 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5040 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5041 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5042 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5043 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5044 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5045 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5046 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Fig.4 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 4) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5051 Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Junction Block (JB). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left on. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition - Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut OFF (time out). This may take up to 3 minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to 3 minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about 3 minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center ( PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5052 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5053 Ignition Off-Draw (IOD) Fuse: Service and Repair IOD FUSE REMOVAL Fig.5 Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA03V389000 > Oct > 03 > Recall 03V389000: Wiring Harness Rerouting/Repair Wiring Harness: Recalls Recall 03V389000: Wiring Harness Rerouting/Repair DEFECT: On certain pickup trucks equipped with manual transmissions, the headlamp and dash wiring harness may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, turn signals, horn, or lighting systems. This could affect driver visibility, could prevent a driver from sounding a warning by using the horn, and, when the turn signals are inoperative, the driver cannot use them to signal intent to turn, increasing the risk of a crash. REMEDY: Dealers will reroute the wire harness and repair the harness if necessary. The manufacturer has reported that owner notification began on November 3, 2003. Owners may contact DaimlerChrysler at 1-800-992-1997. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing Technical Service Bulletin # C35 Date: 031001 Recall - Dash/Headlamp Wiring Harness Routing October 2003 Dealer Service Instructions for: Safety Recall No. C35 Headlamp and Dash Wiring Harness Models 2001-2003 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles equipped with a manual transmission (Sales Code DDK or DDC). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The headlamp and dash wiring harness on about 49,000 of the above vehicles may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, horn, turn signals and/or lighting systems. Repair The headlamp and dash wiring harness must be rerouted. Any harness wires that are chafed must be repaired as necessary. Parts Information No parts are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT claim entry screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5066 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 schedules 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a 10mm socket, back out the bolt that attaches the 74-way headlamp and dash connector to the instrument panel (I/P) harness connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5067 (Figure 1). 3. Disconnect the 74-way headlamp and dash-to-I/P harness connector. 4. Temporarily move the white I/P harness connector out of the way by placing it up over the hood release cable. 5. Press the release tab on the black 74-way connector surround sleeve and then pull the gray connector and sleeve assembly off of its steel mounting bracket. 6. Inspect the headlamp and dash wiring harness take-out that is routed near the clutch pedal for evidence of chafing from contact with the pedal assembly (Figure 1). Wrap any wires that have exposed copper wire strands with high quality electrical tape. 7. Re-route the headlamp and dash wiring harness take-out by moving it under the gray 74-way connector and black surround sleeve assembly and then positioning it to the LEFT side of the connector (move harness from inboard to outboard side of connector/bracket). 8. Install the gray 74-way connector and black surround sleeve assembly back on to its mounting bracket. A "Click" will be heard when it is locked into position. 9. Connect the white 74-way I/P harness connector to the gray 74-way connector and black surround sleeve assembly. 10. Tighten the 74-way connector bolt to 31 in-lbs (3.5 N.m). 11. Actuate the clutch pedal and inspect the harness routing to ensure that the headlamp and dash harness take-out is positioned away from the clutch pedal and linkage. Also ensure that the harness does not interfere with or touch any part of the park brake assembly. 12. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5068 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA03V389000 > Oct > 03 > Recall 03V389000: Wiring Harness Rerouting/Repair Wiring Harness: All Technical Service Bulletins Recall 03V389000: Wiring Harness Rerouting/Repair DEFECT: On certain pickup trucks equipped with manual transmissions, the headlamp and dash wiring harness may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, turn signals, horn, or lighting systems. This could affect driver visibility, could prevent a driver from sounding a warning by using the horn, and, when the turn signals are inoperative, the driver cannot use them to signal intent to turn, increasing the risk of a crash. REMEDY: Dealers will reroute the wire harness and repair the harness if necessary. The manufacturer has reported that owner notification began on November 3, 2003. Owners may contact DaimlerChrysler at 1-800-992-1997. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall Dash/Headlamp Wiring Harness Routing Technical Service Bulletin # C35 Date: 031001 Recall - Dash/Headlamp Wiring Harness Routing October 2003 Dealer Service Instructions for: Safety Recall No. C35 Headlamp and Dash Wiring Harness Models 2001-2003 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles equipped with a manual transmission (Sales Code DDK or DDC). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The headlamp and dash wiring harness on about 49,000 of the above vehicles may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, horn, turn signals and/or lighting systems. Repair The headlamp and dash wiring harness must be rerouted. Any harness wires that are chafed must be repaired as necessary. Parts Information No parts are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT claim entry screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall Dash/Headlamp Wiring Harness Routing > Page 5078 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 schedules 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a 10mm socket, back out the bolt that attaches the 74-way headlamp and dash connector to the instrument panel (I/P) harness connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall Dash/Headlamp Wiring Harness Routing > Page 5079 (Figure 1). 3. Disconnect the 74-way headlamp and dash-to-I/P harness connector. 4. Temporarily move the white I/P harness connector out of the way by placing it up over the hood release cable. 5. Press the release tab on the black 74-way connector surround sleeve and then pull the gray connector and sleeve assembly off of its steel mounting bracket. 6. Inspect the headlamp and dash wiring harness take-out that is routed near the clutch pedal for evidence of chafing from contact with the pedal assembly (Figure 1). Wrap any wires that have exposed copper wire strands with high quality electrical tape. 7. Re-route the headlamp and dash wiring harness take-out by moving it under the gray 74-way connector and black surround sleeve assembly and then positioning it to the LEFT side of the connector (move harness from inboard to outboard side of connector/bracket). 8. Install the gray 74-way connector and black surround sleeve assembly back on to its mounting bracket. A "Click" will be heard when it is locked into position. 9. Connect the white 74-way I/P harness connector to the gray 74-way connector and black surround sleeve assembly. 10. Tighten the 74-way connector bolt to 31 in-lbs (3.5 N.m). 11. Actuate the clutch pedal and inspect the harness routing to ensure that the headlamp and dash harness take-out is positioned away from the clutch pedal and linkage. Also ensure that the harness does not interfere with or touch any part of the park brake assembly. 12. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall Dash/Headlamp Wiring Harness Routing > Page 5080 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Auxiliary Power Outlet: Connector Views Center Power Outlet Cigar Lighter/Power Outlet Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Auxiliary Power Outlet: Electrical Diagrams 8w-41-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 8w-41-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5106 Auxiliary Power Outlet: Service Precautions WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5107 Auxiliary Power Outlet: Description and Operation CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit, and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or On positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet Test WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 3.If not OK, repair the open fused ignition switch output (run/accessory) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity If OK, go to Step 4.If not OK, go to Step 5. 4. Turn the ignition switch to the ON position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6.If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test > Page 5110 Auxiliary Power Outlet: Testing and Inspection Power Outlet Test WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3.If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity If OK, go to Step 4.If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity If OK, go to Step 6.If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Outlet Replacement REMOVAL WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. Fig.2 Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base (Fig. 2). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5113 Fig.3 Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel (Fig. 3). 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5114 Auxiliary Power Outlet: Service and Repair Power Outlet REMOVAL WARNING: REFER TO THE RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. Fig.10 Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5115 Fig.11 Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel (Fig. 11). 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5116 Auxiliary Power Outlet: Service and Repair Rear Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel in the Body for the procedure. 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams Circuit Breaker: Diagrams Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 5120 Circuit Breaker Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 5121 Circuit Breaker: Description and Operation Automatic resetting circuit breakers in the junction block are used to protect the power seat and power window system circuits. These circuit breakers can protect the systems from a short circuit, or overload condition caused by an obstructed or stuck seat adjuster, window glass or regulator. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 5122 Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations Power Distribution Center (PDC): Component Locations Fig.8 Power Distribution Center Location - Typical The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 5127 Power Distribution Center (PDC): Connector Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 5128 Power Distribution Center (PDC): Fuse and Fusible Link Locations Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 5129 Fuses (PDC) Transmission Control Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 Power Distribution Center (PDC): Diagrams C106 C106 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5132 C106 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5133 Power Distribution Center (PDC): Diagrams C107 C107 C107 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5134 Joint Connector No.1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5135 Joint Connector No.2 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5136 Joint Connector No.3 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5137 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION CENTER Fig.9 Power Distribution Center Location - Typical All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to 13 International Standards Organization (ISO) relays (one standard-type and 12 micro-type), two joint connectors (one 16-way and one 26-way) and a 16-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. All of the current from the battery and the generator output enters the PDC through one cable with eyelets that are secured with a nut to the one B(+) terminal stud located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Wiring for the location of complete PDC circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5138 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the Wiring Section for the location of more information on the headlamp and dash wire harness connector locations. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 5. Unlatch and remove the cover from the PDC. 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the B(+) terminal stud in the PDC and remove the eyelet from the stud. 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit off of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. Refer to Power Distribution for the location of complete PDC circuit diagrams and cavity assignments. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 13. Reconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness connector locations. 14. Reconnect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 5143 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5146 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5147 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5148 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5149 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5150 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5151 Fuse: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5152 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 5155 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 5156 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 5157 Fuse: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 5158 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 5163 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Fuse Block: Connector Views Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Junction Block C11 Junction Block C12 Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Fuse Block: Electrical Diagrams 8w-12-6 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 8w-12-7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 8w-12-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 8w-12-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 8w-12-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 8w-12-11 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 8w-12-12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 8w-12-13 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 8w-12-14 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 8w-12-15 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 8w-12-16 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 8w-12-17 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 8w-12-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 8w-12-19 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 8w-12-20 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 8w-12-21 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 8w-12-22 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5207 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5210 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5211 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5212 Fuse Block: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5213 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5214 Fuse Block: Description and Operation JUNCTION BLOCK Fig.6 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 6). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5215 Fuse Block: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 7). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig.8 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 8). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5216 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 Joint Connector No. 1 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 5221 Joint Connector No. 2 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 5222 Joint Connector No. 3 (In PDC) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 5223 Joint Connector No. 4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Fig.4 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 4) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5227 Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Junction Block (JB). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left on. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition - Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut OFF (time out). This may take up to 3 minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to 3 minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about 3 minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center ( PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5228 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5229 Ignition Off-Draw (IOD) Fuse: Service and Repair IOD FUSE REMOVAL Fig.5 Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5235 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5238 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5239 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5240 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5241 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5242 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5243 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5244 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5245 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5248 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5249 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5250 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5251 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5252 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5253 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5254 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5259 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5262 Junction Block (Rear View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5263 Junction Block C1 Junction Block C2 Junction Block C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5264 Junction Block C4 Junction Block C5 Junction Block C6 Junction Block C7 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5265 Junction Block C8 Junction Block C9 Junction Block C10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5266 Junction Block C11 Junction Block C12 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5267 Relay Box: Diagrams Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5268 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5269 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5272 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5273 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5274 Relay Box: Application and ID Power Distribution Center Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5275 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5276 Relay Box: Description and Operation Fig.12 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5277 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig.13 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 13). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse/Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5278 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Fig.4 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 4) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5283 Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Junction Block (JB). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left on. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition - Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut OFF (time out). This may take up to 3 minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to 3 minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about 3 minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center ( PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5284 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 5285 Ignition Off-Draw (IOD) Fuse: Service and Repair IOD FUSE REMOVAL Fig.5 Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA03V389000 > Oct > 03 > Recall 03V389000: Wiring Harness Rerouting/Repair Wiring Harness: Recalls Recall 03V389000: Wiring Harness Rerouting/Repair DEFECT: On certain pickup trucks equipped with manual transmissions, the headlamp and dash wiring harness may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, turn signals, horn, or lighting systems. This could affect driver visibility, could prevent a driver from sounding a warning by using the horn, and, when the turn signals are inoperative, the driver cannot use them to signal intent to turn, increasing the risk of a crash. REMEDY: Dealers will reroute the wire harness and repair the harness if necessary. The manufacturer has reported that owner notification began on November 3, 2003. Owners may contact DaimlerChrysler at 1-800-992-1997. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing Technical Service Bulletin # C35 Date: 031001 Recall - Dash/Headlamp Wiring Harness Routing October 2003 Dealer Service Instructions for: Safety Recall No. C35 Headlamp and Dash Wiring Harness Models 2001-2003 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles equipped with a manual transmission (Sales Code DDK or DDC). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The headlamp and dash wiring harness on about 49,000 of the above vehicles may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, horn, turn signals and/or lighting systems. Repair The headlamp and dash wiring harness must be rerouted. Any harness wires that are chafed must be repaired as necessary. Parts Information No parts are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT claim entry screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5298 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 schedules 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a 10mm socket, back out the bolt that attaches the 74-way headlamp and dash connector to the instrument panel (I/P) harness connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5299 (Figure 1). 3. Disconnect the 74-way headlamp and dash-to-I/P harness connector. 4. Temporarily move the white I/P harness connector out of the way by placing it up over the hood release cable. 5. Press the release tab on the black 74-way connector surround sleeve and then pull the gray connector and sleeve assembly off of its steel mounting bracket. 6. Inspect the headlamp and dash wiring harness take-out that is routed near the clutch pedal for evidence of chafing from contact with the pedal assembly (Figure 1). Wrap any wires that have exposed copper wire strands with high quality electrical tape. 7. Re-route the headlamp and dash wiring harness take-out by moving it under the gray 74-way connector and black surround sleeve assembly and then positioning it to the LEFT side of the connector (move harness from inboard to outboard side of connector/bracket). 8. Install the gray 74-way connector and black surround sleeve assembly back on to its mounting bracket. A "Click" will be heard when it is locked into position. 9. Connect the white 74-way I/P harness connector to the gray 74-way connector and black surround sleeve assembly. 10. Tighten the 74-way connector bolt to 31 in-lbs (3.5 N.m). 11. Actuate the clutch pedal and inspect the harness routing to ensure that the headlamp and dash harness take-out is positioned away from the clutch pedal and linkage. Also ensure that the harness does not interfere with or touch any part of the park brake assembly. 12. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5300 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA03V389000 > Oct > 03 > Recall 03V389000: Wiring Harness Rerouting/Repair Wiring Harness: All Technical Service Bulletins Recall 03V389000: Wiring Harness Rerouting/Repair DEFECT: On certain pickup trucks equipped with manual transmissions, the headlamp and dash wiring harness may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, turn signals, horn, or lighting systems. This could affect driver visibility, could prevent a driver from sounding a warning by using the horn, and, when the turn signals are inoperative, the driver cannot use them to signal intent to turn, increasing the risk of a crash. REMEDY: Dealers will reroute the wire harness and repair the harness if necessary. The manufacturer has reported that owner notification began on November 3, 2003. Owners may contact DaimlerChrysler at 1-800-992-1997. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing Technical Service Bulletin # C35 Date: 031001 Recall - Dash/Headlamp Wiring Harness Routing October 2003 Dealer Service Instructions for: Safety Recall No. C35 Headlamp and Dash Wiring Harness Models 2001-2003 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles equipped with a manual transmission (Sales Code DDK or DDC). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The headlamp and dash wiring harness on about 49,000 of the above vehicles may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, horn, turn signals and/or lighting systems. Repair The headlamp and dash wiring harness must be rerouted. Any harness wires that are chafed must be repaired as necessary. Parts Information No parts are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT claim entry screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5310 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 schedules 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Using a 10mm socket, back out the bolt that attaches the 74-way headlamp and dash connector to the instrument panel (I/P) harness connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5311 (Figure 1). 3. Disconnect the 74-way headlamp and dash-to-I/P harness connector. 4. Temporarily move the white I/P harness connector out of the way by placing it up over the hood release cable. 5. Press the release tab on the black 74-way connector surround sleeve and then pull the gray connector and sleeve assembly off of its steel mounting bracket. 6. Inspect the headlamp and dash wiring harness take-out that is routed near the clutch pedal for evidence of chafing from contact with the pedal assembly (Figure 1). Wrap any wires that have exposed copper wire strands with high quality electrical tape. 7. Re-route the headlamp and dash wiring harness take-out by moving it under the gray 74-way connector and black surround sleeve assembly and then positioning it to the LEFT side of the connector (move harness from inboard to outboard side of connector/bracket). 8. Install the gray 74-way connector and black surround sleeve assembly back on to its mounting bracket. A "Click" will be heard when it is locked into position. 9. Connect the white 74-way I/P harness connector to the gray 74-way connector and black surround sleeve assembly. 10. Tighten the 74-way connector bolt to 31 in-lbs (3.5 N.m). 11. Actuate the clutch pedal and inspect the harness routing to ensure that the headlamp and dash harness take-out is positioned away from the clutch pedal and linkage. Also ensure that the harness does not interfere with or touch any part of the park brake assembly. 12. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > C35 > Oct > 03 > Recall - Dash/Headlamp Wiring Harness Routing > Page 5312 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications ALIGNMENT Alignment Specifications Dakota NOTE: All alignment specifications are in degrees. Alignment Specifications Dakota R/T Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5317 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. OPERATION CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5318 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 5321 Alignment: Service and Repair Wheel Alignment Camber STANDARD PROCEDURE-CAMBER NOTE: 4x4 suspension height measurement must be performed before alignment. Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. Camber and Caster Adjustment STANDARD PROCEDURE-CAMBER AND CASTER ADJUSTMENT NOTE: 4x4 suspension height measurement must be performed before alignment. Camber and caster angle adjustments involve changing the position of the upper suspension arm Divot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. Caster STANDARD PROCEDURE-CASTER NOTE: 4x4 suspension height measurement must be performed before alignment. Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. Toe Adjustment STANDARD PROCEDURE-TOE ADJUSTMENT NOTE: 4x4 suspension height measurement must be performed before alignment. 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. Leave the engine running. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 5322 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications. 6. Turn off engine. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5328 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5329 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5334 Front Steering Knuckle: Service and Repair KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft. 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover C-3894A. 6. Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 7. Remove the upper ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover MB-991113. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5335 8. Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A and remove the knuckle. 9. Remove the hub/bearing from the steering knuckle. INSTALLATION NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 166 Nm (123 ft. lbs.). CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 2. Install the knuckle onto the upper and lower ball joint. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 81 Nm (60 ft. lbs.) and the lower ball joint nut to 183 Nm (135 ft. lbs.) then install cotter pins. Grease the lower ball joint. 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 88 Nm (65 ft. lbs.). 6. Install the front halfshaft. 7. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 8. Install the wheel and tire assembly. 9. Remove the support and lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5341 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5342 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5343 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications The power steering fluid reservoir is equipped with a dipstick to indicate fluid level. Fluid level should be at the "HOT" mark if the vehicle has been operating; "FULL COLD" if not operated for at least 6 hrs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 5346 Power Steering Fluid: Fluid Type Specifications Type Mopar ATF+4 Automatic Transmission Fluid Use only Mopar ATF+4 Automatic Transmission Fluid. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5347 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5348 Power Steering Fluid: Description and Operation FLUID DESCRIPTION The recommended fluid for the power steering system is Mopar ATF+4, MS 9602. Mopar ATF+4, MS 9602, Automatic Transmission Fluid when new is red in color. The ATF 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 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5349 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR (MS-9602) 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. Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602). Do not overfill the power steering system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Siphon the power steering system. 2. Disconnect the return hose at the pump. 3. Raise and support the vehicle. 4. Disconnect the return hose at the cooler. 5. Remove the cooler mounting nut and bolt. 6. Remove the cooler. INSTALLATION 1. Install the cooler. 2. Install the cooler mounting nut and bolt. 3. Reconnect the return hose at the cooler. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the pump. 6. Refill the power steering system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Line Pressure Line 23 ft. lbs. Power Steering Line Return Line 23 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 5356 Power Steering Line/Hose: Service and Repair HOSES REMOVAL- RETURN HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose at the gear. 5. Remove the pressure hose from the vehicle. REMOVAL- PRESSURE HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION - RETURN HOSE 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. Tighten the hose to 31 Nm (23 ft. lbs.). 3. Reconnect the return hose at the gear. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. INSTALLATION - PRESSURE HOSE 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 31 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5361 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5362 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5363 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pump Mounting Bolts 21 ft.lb Flow Control Valve 60 ft.lb Pressure Line 25 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5366 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Relief Pressure 1450 +/- 50 psi Flow Rate 2.4 - 2.8 gal/min At 1500 RPM Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5367 Power Steering Pump: Description and Operation PUMP DESCRIPTION The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. Trailer tow option vehicles are equipped with a power steering pump oil cooler. On the 5.2L and 5.9L the oil cooler is mounted to the engine block. On the 4.7L the oil cooler is mounted to the power steering pump. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump and. The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5368 Power Steering Pump: Testing and Inspection DIAGNOSIS AND TESTING - PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. Plastic pump reservoirs can be replace and the reservoir O-ring. Check for leaks in the following areas: Pump shaft seal behind the pulley - Pump to reservoir O-ring - Reservoir cap - Pressure and return lines - Flow control valve fitting Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump REMOVAL 1. Remove the serpentine drive belt. 2. Remove return hose from the pump reservoir and drain the pump. 3. Remove power steering pressure switch connector and remove pressure line from the bottom of the pump. 4. Remove the oil cooler mounting bolt from the pump bracket if equipped. 5. Remove 3 pump mounting bolts through pulley access holes. 6. Remove the pump from the left cylinder head. INSTALLATION 1. Align the pump with the mounting holes in the left cylinder head. 2. Install 3 pump mounting bolts through the pulley access holes. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Install the oil cooler to the pump bracket if equipped. Install the oil cooler mounting bolt. 4. Install the pressure line and return hose to the pump. Tighten the pressure line to 35 Nm (25 ft. lbs.). 5. Install power steering pressure switch connector. 6. Install the serpentine drive belt. 7. Fill the power steering pump and perform Power Steering Pump Initial Operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5371 Power Steering Pump: Service and Repair Power Steering Pump Pulley PULLEY REMOVAL CAUTION: On vehicles equipped with the 4.7L, Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333. INSTALLATION CAUTION: On vehicles equipped with the 4.7L, Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-B flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 5372 Power Steering Pump: Tools and Equipment SPECIAL TOOLS Part 1 0f 2 Part 2 0f 2 POWER STEERING PUMP Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Torque Torque Power Steering Pressure Switch 14-22 Nm 124-195 In. Lbs Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5377 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5378 Power Steering Pressure Switch (2.5L/4.7L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5383 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Rack and Pinion Steering Gear Gear To Frame Bolts 200 ft. lbs. Rack and Pinion Steering Gear Intermediate Shaft Bolt 42 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5387 Steering Gear: Description and Operation GEAR DESCRIPTION A rack and pinion steering gears is made up of two main components, the pinion shaft and the rack. The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. If a boot seal becomes damaged, the steering gear must be removed to replace the boot seal. OPERATION The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5388 Steering Gear: Service and Repair GEAR REMOVAL 1. Raise and support the vehicle. 2. Remove the splash shield from under the front end to gain access to the gear. 3. Remove the nuts from the tie rod ends. 4. Separate tie rod ends from the knuckles with Puller C-3894-A. 5. Remove the power steering lines from the gear. 6. Remove the lower coupler bolt and slide the coupler off the gear. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5389 7. Remove the mounting bolts from the gear to the front crossmember. Slide the gear to the right side of the vehicle. Then tilt the left end of the gear down and remove the gear. INSTALLATION NOTE: Before installing gear inspect bushings and replace if worn or damaged. 1. Install gear on front crossmember and tighten mounting bolts to 271 Nm (200 ft. lbs.). 2. Slide shaft coupler onto gear. Install new bolt and tighten to 49 Nm (36 ft. lbs.). 3. Clean tie rod end studs and knuckle tapers. 4. Install tie rod ends into the steering knuckles and tighten the nuts to 81 Nm (60 ft. lbs.). 5. Install power steering lines to steering gear and tighten the hose to 31 Nm (23 ft. lbs.). 6. Install the splash shield. 7. Remove support and lower vehicle. 8. Fill system with fluid. 9. Adjust the toe position. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5390 Steering Gear: Tools and Equipment RACK AND PINION STEERING GEAR Puller C-3894-A Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Knuckle Nut 60 ft. lbs. Tie Rod End Jam Nut 55 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5395 Tie Rod End: Description and Operation BOOT SEAL DESCRIPTION The boot seal is a bellows type seal the protects dirt and contaminates from entering the open gears of the rack and pinion unit. OPERATION The boot seal operates with the inward and outward motions of the rack and pinion, If the seal is worn or ripped in any way it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5396 Tie Rod End: Service and Repair TIE ROD END REMOVAL - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Loosen the jam nut. 2. Remove the outer tie rod end nut at the steering knuckle. 3. Separate the tie rod ball stud from the knuckle with Remover MB-991113. 4. Unthread the outer tie rod end from the inner tie rod. INSTALLATION - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end onto the inner tie rod, to its original position. 2. Install the outer tie rod end into the steering knuckle. 3. Tighten the ball stud nut on the steering knuckle to 81 Nm (60 ft. lbs.). 4. Tighten jam nut to 75 Nm (55 ft. lbs.). 5. Set wheel toe pattern. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect Technical Service Bulletin # D47 Date: 041221 Recall - Upper Ball Joint Defect December 2004 Dealer Service Instructions for: Safety Recall D47 - Upper Ball Joints 2000 - 2003 (AN) Dodge Dakota 4x4 Pick-Up Truck 2000 - 2003 (DN) Dodge Durango 4x4 NOTE: This notification applies only to the above vehicles built through December 31, 2002 (MDH 1231XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Water may enter into the front suspension upper ball joints on about 600,000 of the above vehicles and cause corrosion and premature wear. Excessive wear of the upper ball joint may cause the front wheel to separate from the vehicle and result in a loss of control. A seriously worn ball joint may cause a "clunking" noise to develop in the front suspension. However, vehicle occupants may not always hear this "clunking" noise. Losing control of the vehicle could result in a crash. Repair Both front suspension upper ball joints must be replaced. Parts Information Special Tools Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5406 The special tool applies to this service procedure: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package if necessary plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this recall on DealerCONNECT, select TechCONNECT on the Service tab, click on "Search Bulletins/Recalls", enter the recall code and then click on the "Search" button. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5407 Replace Upper Ball Joints 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Position a hydraulic jack under the left side lower control arm and raise the jack to unload the rebound bumper. 4. Remove the cotter pin from the upper ball joint castle nut. 5. Remove the upper ball joint castle nut from the upper ball joint stud. 6. Using a die grinder equipped with a cut-off wheel, grind an "X" through each of the three upper ball joint rivet heads (Figure 1). CAUTION: Do not grind into the control arm. 7. Using an air chisel, chisel the three rivet heads off of the upper ball joint. 8. Punch out the rivets using a drift and hammer. 9. Separate the upper ball joint from the steering knuckle with special tool MB991113. 10. Remove and discard the old ball joint. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5408 11. Using 100 grit emery cloth, lightly sand the top surface of the steering knuckle to remove any rust and/or scale from the steering knuckle (Figure 2). 12. Insert the bolts supplied with the ball joint package from the bottom side of the control arm (Figure 3). 13. Place the new ball joint onto the control arm and install retaining nuts (Figure 3). Tighten the nuts to 50 ft. lbs. (68 N.m). 14. Position the steering knuckle onto the upper ball joint stud. 15. Install the castle nut onto the ball joint stud. Tighten the upper ball joint castle nut to 60 ft. lbs. (81 Nm). NOTE: If the castle nut slots do not line up with the cotter pin hole in the ball joint stud, continue tightening the nut until the next set of castle nut slots line up with the cotter pin hole. Do not loosen the nut. 16. Install the cotter pin through the castle nut and secure it by bending the arms of the pin. 17. Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs (135 N.m). 18. Repeat Steps 3 through 17 on the right side of the vehicle. 19. Lower the vehicle from the hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5409 20. Place the vehicle on an alignment rack. 21. Install the wheel alignment equipment onto the vehicle per alignment equipment manufacturer's instructions and set toe to +/-.10° (+/- 0.06°). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA04V596000 > Dec > 04 > Recall 04V596000: Upper Ball Joint Replacement Ball Joint: Recalls Recall 04V596000: Upper Ball Joint Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2000-2003 Dodge/Durango 2000-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number: 04V596000 Recall Date: Dec 15, 2004 COMPONENT: Suspension: Front: Control Arm: Upper Ball Joint POTENTIAL NUMBER OF UNITS AFFECTED: 592707 SUMMARY: On certain sport utility vehicles and pickup trucks equipped with four-wheel drive (4X4), if moisture leaks into the front suspension upper ball joint, evacuation of the lubricant and corrosion of the joint may cause the joint to wear over an extended period of time. This could cause a clunking noise in the front suspension, which may not always be heard by the vehicle occupants. CONSEQUENCE: Excessive wear in the upper ball joint may allow it to separate, which could result in loss of control of the vehicle. REMEDY: Dealers will replace the front suspension upper ball joints. This safety improvement campaign began on December 21, 2004. Owners can contact DaimlerChrysler at 1-800-853-1403. NOTES: This action is deemed a safety improvement campaign and is not being conducted under the safety act. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect Technical Service Bulletin # D47 Date: 041221 Recall - Upper Ball Joint Defect December 2004 Dealer Service Instructions for: Safety Recall D47 - Upper Ball Joints 2000 - 2003 (AN) Dodge Dakota 4x4 Pick-Up Truck 2000 - 2003 (DN) Dodge Durango 4x4 NOTE: This notification applies only to the above vehicles built through December 31, 2002 (MDH 1231XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Water may enter into the front suspension upper ball joints on about 600,000 of the above vehicles and cause corrosion and premature wear. Excessive wear of the upper ball joint may cause the front wheel to separate from the vehicle and result in a loss of control. A seriously worn ball joint may cause a "clunking" noise to develop in the front suspension. However, vehicle occupants may not always hear this "clunking" noise. Losing control of the vehicle could result in a crash. Repair Both front suspension upper ball joints must be replaced. Parts Information Special Tools Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5419 The special tool applies to this service procedure: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package if necessary plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this recall on DealerCONNECT, select TechCONNECT on the Service tab, click on "Search Bulletins/Recalls", enter the recall code and then click on the "Search" button. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5420 Replace Upper Ball Joints 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Position a hydraulic jack under the left side lower control arm and raise the jack to unload the rebound bumper. 4. Remove the cotter pin from the upper ball joint castle nut. 5. Remove the upper ball joint castle nut from the upper ball joint stud. 6. Using a die grinder equipped with a cut-off wheel, grind an "X" through each of the three upper ball joint rivet heads (Figure 1). CAUTION: Do not grind into the control arm. 7. Using an air chisel, chisel the three rivet heads off of the upper ball joint. 8. Punch out the rivets using a drift and hammer. 9. Separate the upper ball joint from the steering knuckle with special tool MB991113. 10. Remove and discard the old ball joint. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5421 11. Using 100 grit emery cloth, lightly sand the top surface of the steering knuckle to remove any rust and/or scale from the steering knuckle (Figure 2). 12. Insert the bolts supplied with the ball joint package from the bottom side of the control arm (Figure 3). 13. Place the new ball joint onto the control arm and install retaining nuts (Figure 3). Tighten the nuts to 50 ft. lbs. (68 N.m). 14. Position the steering knuckle onto the upper ball joint stud. 15. Install the castle nut onto the ball joint stud. Tighten the upper ball joint castle nut to 60 ft. lbs. (81 Nm). NOTE: If the castle nut slots do not line up with the cotter pin hole in the ball joint stud, continue tightening the nut until the next set of castle nut slots line up with the cotter pin hole. Do not loosen the nut. 16. Install the cotter pin through the castle nut and secure it by bending the arms of the pin. 17. Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs (135 N.m). 18. Repeat Steps 3 through 17 on the right side of the vehicle. 19. Lower the vehicle from the hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > D47 > Dec > 04 > Recall - Upper Ball Joint Defect > Page 5422 20. Place the vehicle on an alignment rack. 21. Install the wheel alignment equipment onto the vehicle per alignment equipment manufacturer's instructions and set toe to +/-.10° (+/- 0.06°). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA04V596000 > Dec > 04 > Recall 04V596000: Upper Ball Joint Replacement Ball Joint: All Technical Service Bulletins Recall 04V596000: Upper Ball Joint Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2000-2003 Dodge/Durango 2000-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number: 04V596000 Recall Date: Dec 15, 2004 COMPONENT: Suspension: Front: Control Arm: Upper Ball Joint POTENTIAL NUMBER OF UNITS AFFECTED: 592707 SUMMARY: On certain sport utility vehicles and pickup trucks equipped with four-wheel drive (4X4), if moisture leaks into the front suspension upper ball joint, evacuation of the lubricant and corrosion of the joint may cause the joint to wear over an extended period of time. This could cause a clunking noise in the front suspension, which may not always be heard by the vehicle occupants. CONSEQUENCE: Excessive wear in the upper ball joint may allow it to separate, which could result in loss of control of the vehicle. REMEDY: Dealers will replace the front suspension upper ball joints. This safety improvement campaign began on December 21, 2004. Owners can contact DaimlerChrysler at 1-800-853-1403. NOTES: This action is deemed a safety improvement campaign and is not being conducted under the safety act. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications Ball Joint: Specifications Ball Joint Wear Limit Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................................... 0.060" Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications > Page 5429 Ball Joint: Specifications Torque Specifications Wear Limit See Note If the travel exceeds 0.060 in. replace the lower suspension arm. Wear Limit 0.060 inch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint DIAGNOSIS AND TESTING - LOWER BALL JOINT NOTE: If the ball joint is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower suspension arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. NOTE: The upper suspension arms must not contact the rebound bumpers. 2. Remove the tire and wheel assemblies. 3. Mount a dial indicator solidly to the underside of the lower suspension arm. 4. Position indicator plunger against the bottom surface of the steering knuckle lower ball joint boss. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle lower ball joint boss. 5. Position a pry bar over the top of the upper suspension arm and under the pivot bar of the upper suspension arm. Pry down on the upper suspension arm and then zero the dial indicator. 6. Reposition the pry bar under the upper suspension arm and on top of the jounce/rebound bracket. Pry up on the upper suspension arm and record the dial indicator reading. 7. If the travel exceeds 1.52 mm (0.060 inch), replace the lower ball joint. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5432 Ball Joint: Testing and Inspection Upper Ball Joint DIAGNOSIS AND TESTING - UPPER BALL JOINT 1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). 2. Mount a dial indicator solidly on the upper suspension arm. 3. Position the indicator plunger against the back side of the upper ball joint boss of the steering knuckle. 4. Grasp the top of the tire and pull outward, then zero the dial indicator 5. Grasp the top of the tire and push inward and record the dial indicator reading. 6. If lateral movement is greater than 1.52 mm (0.060 inch), replace upper suspension arm. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 5433 Ball Joint: Service and Repair LOWER BALL JOINT REMOVAL 1. Remove the cotter pin, nut lock, and spring washer from the front drive shaft. 2. Remove the hub nut and washer from the front drive shaft. 3. Raise the vehicle. 4. Remove the tire and wheel assembly. 5. Unload the torsion bar spring load by turning the adjuster bolt counterclockwise. 6. Remove the adjuster bolt, bearing, swivel, and anchor from the torsion bar. 7. Remove the stabilizer bar retainer bolts and retainers from both the lower suspension arms. Swivel the stabilizer bar away from the lower suspension arm. 8. Remove the shock absorber lower mounting bolt. 9. Remove the rear lower suspension arm mounting bolt and loosen the front bolt. 10. Remove the front drive shaft bolts from the inner CV joint flange. 11. Remove the driveshaft. 12. Remove the front ball joint cotter pin and nut. Separate the ball joint from the knuckle with special tool C-4150A (Remover). 13. Support the knuckle with a jack stand and raise the jack up to gain access to the lower ball joint. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 5434 14. On vehicles equipped with ball joints that are retained with a snap-ring, remove the snap ring. If the vehicle's ball joint is not retained with a snap ring (joint retained with four stakes), Remove the four stakes on the ball joint flange using a chisel and hammer. 15. Remove the ball joint boot. 16. Remove the ball joint using special tools C-4212-F (press), 8345 (receiver), and C4212-3 (driver). INSTALLATION 1. Install the ball joint into the control arm and press in using special tools C-4212-F (press) and 6758 (driver). 2. Install the ball joint boot. 3. If the new ball joint is equipped with a snap ring, Install the snap ring. If the new ball joint is not retained with a snap ring (joint retained with four stakes), stake the ball joint flange in four places using a chisel and hammer. 4. Remove the support that supported the knuckle. 5. Install the ball joint into the steering knuckle and tighten the ball joint nut to 183 Nm (135 ft. lbs.). 6. Lubricate the ball joint. 7. Install the rear lower suspension arm mounting bolt. 8. Install the half shaft and tighten to 244 Nm (180 ft. lbs.). 9. Install the shock absorber and tighten to 108 Nm (80 ft. lbs.). 10. Install the stabilizer bar retainer bolts and tighten to 34 Nm (25 ft. lbs.). 11. Tighten the rear lower suspension arm mounting bolt to 190 Nm (140 ft. lbs.). 12. Tighten the front lower suspension arm mounting bolt to 108 Nm (80 ft. lbs.). 13. Install the adjuster bolt, bearing, swivel and anchor to the torsion bar. 14. Reload the torsion bar. 15. Install the tire and wheel assembly. 16. Adjust the vehicle ride height. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension CONTROL ARM BUSHINGS REMOVAL 1. Remove the control arm from the vehicle. 2. Mount the control arm securely in a vise. 3. Remove the nut and washer from the control arm shaft. 4. Install the bushing tool. 5. Press out the old bushings. INSTALLATION 1. Install the bushing in the control arm and inserted over the shaft. 2. Install the bushing tool. 3. Press the bushing into the control arm. 4. Install the washer and nut to the control arm shaft. Torque the nut to 167 Nm (130 ft. lbs.) specification. 5. Remove the control arm from the vise. 6. Install the control arm in the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 5440 Control Arm Bushing: Service and Repair Rear Suspension CONTROL ARM BUSHINGS REMOVAL 1. Remove the spring from the vehicle. 2. Position the spring eye in a press. 3. Press the bushing out with an appropriate size driver. INSTALLATION 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Install the spring on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5444 Front Steering Knuckle: Service and Repair KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft. 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover C-3894A. 6. Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 7. Remove the upper ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover MB-991113. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5445 8. Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A and remove the knuckle. 9. Remove the hub/bearing from the steering knuckle. INSTALLATION NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 166 Nm (123 ft. lbs.). CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 2. Install the knuckle onto the upper and lower ball joint. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 81 Nm (60 ft. lbs.) and the lower ball joint nut to 183 Nm (135 ft. lbs.) then install cotter pins. Grease the lower ball joint. 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 88 Nm (65 ft. lbs.). 6. Install the front halfshaft. 7. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 8. Install the wheel and tire assembly. 9. Remove the support and lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Stabilizer Bar Link Nuts 40 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Rear Suspension Spring ( Coil / Leaf ): Specifications Spring U-Bolt Nuts 110 ft. lbs. Spring Eye Nut 120 ft. lbs. Spring Shackle Nuts 120 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Rear > Page 5454 Suspension Spring ( Coil / Leaf ): Specifications Spring U-Bolt Nuts 110 ft.lb Spring Eye Nut 120 ft.lb Spring Shackle Nuts 120 ft.lb Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Leaf Spring Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Spring DESCRIPTION The 4x2 rear suspension system uses a 4-leaf two stage or 5-leaf single stage springs and a solid drive axle. The 4x4 rear suspension system uses only a 4-leaf two stage spring and solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Leaf Spring > Page 5457 Suspension Spring ( Coil / Leaf ): Description and Operation Rear SPRING DESCRIPTION The 4x2 rear suspension system uses a 4-leaf two stage or 5-leaf single stage springs and a solid drive axle. The 4x4 rear suspension system uses only a 4-leaf two stage spring and solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5458 Suspension Spring ( Coil / Leaf ): Testing and Inspection DIAGNOSIS AND TESTING - SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing rubber. If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips, and broken center bolts. Refer to Spring and Shock Absorber Diagnosis chart for additional information. SPRING AND SHOCK ABSORBER Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring REMOVAL CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. 1. Raise the vehicle at the frame. 2. Use a hydraulic jack to relieve the axle weight. 3. Remove the wheel and tire assemblies. 4. Remove the nuts, the U-bolts and spring plate from the axle and . 5. Remove the nut and bolt from the spring front eye. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 5461 6. Remove the nut and bolt that attaches the spring shackle to the rear frame bracket. 7. Remove the spring from the vehicle. INSTALLATION CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. 1. Install the spring shackle on the spring finger tight. 2. Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align front spring eye with the bolt hole in the front frame bracket. Install the spring eye bolt and nut and tighten the spring eye nut finger-tight. 4. Align spring shackle eye with the bolt hole in the rear frame bracket. Install the bolt and nut and tighten the spring shackle eye nut finger-tight. 5. Install the spring seat (4x4 only), U-bolts, spring plate and nuts. 6. Tighten the U-bolt nuts to 149 Nm (110 ft. lbs.). 7. Install the wheel and tire assemblies. 8. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. 9. Tighten the spring eye pivot bolt nut and all shackle nuts to 163 Nm (120 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 5462 Suspension Spring ( Coil / Leaf ): Service and Repair Rear SPRING REMOVAL CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. 1. Raise the vehicle at the frame. 2. Use a hydraulic jack to relieve the axle weight. 3. Remove the wheel and tire assemblies. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 5463 4. Remove the nuts, the U-bolts and spring plate from the axle and. 5. Remove the nut and bolt from the spring front eye. 6. Remove the nut and bolt that attaches the spring shackle to the rear frame bracket. 7. Remove the spring from the vehicle. 8. Remove the shackle from the spring. INSTALLATION CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. 1. Install the spring shackle on the spring finger tight. 2. Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align front spring eye with the bolt hole in the front frame bracket. Install the spring eye bolt and nut and tighten the spring eye nut finger-tight. 4. Align spring shackle eye with the bolt hole in the rear frame bracket. Install the bolt and nut and tighten the spring shackle eye nut finger-tight. 5. Install the spring seat (4x4 only), U-bolts, spring plate and nuts. 6. Tighten the U-bolt nuts to 149 Nm (110 ft. lbs.). 7. Install the wheel and tire assemblies. 8. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. 9. Tighten the spring eye pivot bolt nut and all shackle nuts to 163 Nm (120 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Shock Absorber Upper Nut 19 ft. lbs. Shock Absorber Lower Bolts 80 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 5468 Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Bolt 70 ft. lbs. Shock Absorber Upper Bolt 70 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front SHOCK DESCRIPTION The top of the low-pressure gas charged shock is bolted to the frame. The bottom of the shock is bolted to the lower suspension arm. OPERATION The shock absorbers dampen jounce and rebound of the vehicle over various road conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5471 Suspension Strut / Shock Absorber: Description and Operation Rear SHOCK DESCRIPTION The top of the shock absorbers are bolted to the body crossmember. The bottom of the shocks are bolted to the axle brackets. The axle brackets are staggered one ahead of the axle and one behind. OPERATION Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 5472 Suspension Strut / Shock Absorber: Testing and Inspection DIAGNOSIS AND TESTING - SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil base lubricants will deteriorate the bushing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 5473 Suspension Strut / Shock Absorber: Service and Repair SHOCK REMOVAL 1. Raise and support vehicle. 2. Remove the upper shock absorber nut, retainer and grommet. 3. Remove the lower bolt and remove the shock absorber. INSTALLATION NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite 242 on existing nut. 1. Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud. Insert the shock absorber through the frame bracket hole. 2. Install the lower bolt and tighten the bolt to 108 Nm (80 ft. lbs.). 3. Install the upper grommet, retainer (upper retainer is stamped with a U) and new nut or use Mopar Lock 'N Seal or Loctite 242 on existing nut, on the shock absorber stud. Tighten nut to 26 Nm (19 ft. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Jounce Bumper Bolts 45 ft. lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Description and Operation Torsion Bar: Description and Operation TORSION BAR DESCRIPTION The front of the bar mounts to the back side of the lower suspension arm. The rear end of the bar is mounted in a anchor that rests in the frame crossmember. OPERATION The torsion bars are used to control ride height and ride quality. The vehicle height is adjusted through an anchor adjustment bolt that increases or decreases the angle of the torsion bar. Increasing or decreasing the bar angle changes the angle of the suspension arms. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Description and Operation > Page 5480 Torsion Bar: Service and Repair TORSION BARREMOVAL CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. 1. Raise and support the vehicle with the front suspension hanging. 2. Turn the adjustment bolt counterclockwise to release spring load. NOTE: Count and record the number of turns for installation reference. 3. Remove the adjustment bolt from swivel. 4. Remove torsion bar and anchor. Remove anchor from torsion bar. 5. Remove all foreign material from torsion bar mounting in anchor and suspension arm. 6. Inspect adjustment bolt, bearing and swivel for damage. INSTALLATION CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. 1. Insert torsion bar ends into anchor and suspension arm. 2. Position anchor and bearing in frame crossmember. Install adjustment bolt through bearing, anchor and into the swivel. 3. Turn adjustment bolt clockwise the recorded amount of turns. 4. Lower vehicle and adjust the front suspension height. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Half Shaft Nut ...................................................................................................................................... .............................................. 244 Nm (180 Ft Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Fig.6 Correct Vehicle Lifting Locations - Typical STANDARD PROCEDURE HOISTING RECOMMENDATIONS Floor Jack CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - Aluminum differential. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. When properly positioned, a floor jack can be used to lift a Dakota vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. Hoist WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVE TRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: DO NOT LET THE REAR WHEELS/AXLE HANG UNSUPPORTED WHEN THE VEHICLE IS LIFTED WITH THE PARKING BRAKE APPLIED. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 6). A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. A ramp-type, drive-on hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation SPARE TIRE DESCRIPTION The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation > Page 5496 Spare Tire: Service and Repair SPARE TIRE WINCH REMOVAL 1. Remove spare tire. 2. Remove bolts attaching spare tire winch to crossmember. 3. Disengage clip attaching extension tube to spare tire winch. 4. Separate spare tire winch from vehicle. INSTALLATION 1. Position extension tube on spare tire winch and engage clip. 2. Position spare tire winch on vehicle. 3. Install bolts attaching spare tire winch to spare tire bracket. 4. Install spare tire. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 5501 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5502 Wheels: Specifications Wheel Lug Nut 85 to 115 ft. lbs. CAUTION: DO NOT USE CHROME PLATED LUG NUTS WITH CHROME PLATED WHEELS. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5503 Wheels: Description and Operation WHEELS DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5504 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Half Shaft Nut ...................................................................................................................................... .............................................. 244 Nm (180 Ft Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 5516 Wheel Fastener: Specifications Caution: Do not use chrome plated lug nuts with chrome plated wheels. Wheel Lug Nut 1/2 x 20 with 60 degree Cone 85-115 ft.lbs. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations Accumulator HVAC: Locations The accumulator is mounted in the engine compartment between the A/C evaporator outlet tube and the compressor inlet. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 5521 Accumulator HVAC: Description and Operation The accumulator is mounted in the engine compartment between the A/C evaporator outlet tube and the compressor inlet. Refrigerant enters the accumulator canister as a low pressure vapor through the inlet tube. Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 5522 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the loss of pressure switch. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the accumulator refrigerant line couplers. 5. Loosen the screw that secures the accumulator retaining band to the support bracket on the dash panel. Fig.8 Accumulator And Lines 6. Disconnect the suction line refrigerant line fastener from the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Disconnect the accumulator inlet tube refrigerant line secondary clip from the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Pull the accumulator and retaining band unit forward until the screw in the band is clear of the slotted hole in the support bracket on the dash panel. 9. Remove the accumulator from the vehicle. INSTALLATION 1. Install the accumulator and retaining band as a unit by sliding the screw in the band into the slotted hole in the support bracket on the dash panel. 2. Remove the tape or plugs from the refrigerant line fittings on the accumulator inlet tube and the evaporator outlet tube. Connect both refrigerant lines to the accumulator. Tighten the fasteners to 25.99 ± 3.39 Nm (230 ± 30 in. lbs.). 3. Tighten the accumulator retaining band screw to 4.5 Nm (40 in. lbs.). 4. Plug the wire harness connector into the low pressure cycling clutch switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. See Refrigerant System Evacuate in the Service Procedures. 7. Charge the refrigerant system. See Refrigerant System Charge in the Service Procedures. NOTE: If the accumulator is replaced, add 90 milliliters (3 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations The single mode door actuator is located on the driver side end of the heater-A/C housing unit, in the middle of the distribution housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5527 Air Door Actuator / Motor: Diagrams Blend Door Actuator Mode Door Actuator Recirculation Door Actuator Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5528 Air Door Actuator / Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5529 Air Door Actuator / Motor: Description and Operation BLEND DOOR ACTUATOR The blend door actuator is a reversible, 12 volt Direct Current (DC), servo motor The blend door actuator is interchangeable with actuators for the mode door and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the blend air door. The blend door actuator does not require mechanical indexing to the blend door linkage, as it is electronically calibrated by the heater-A/C control module. The blend door actuator cannot be adjusted or repaired and if damaged or faulty it must be replaced. The blend door actuator is connected to the heater- A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The blend door actuator can move the blend air door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the blend air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The heater-A/C control module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. MODE DOOR ACTUATOR The mode door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The single mode door actuator is located on the driver side end of the heater-A/C housing unit, in the middle of the distribution housing. The mode door actuator is mechanically connected to the mode cam. The mode door actuator is interchangeable with the actuators for the blend air door(s) and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater- A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the mode door. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the heater-A/C control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty it must be replaced. The mode door actuator is connected to the heater- A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The mode door actuator can move the mode cam in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the mode cam will move in one direction. When the module reverses the polarity of the voltage to the motor, the mode cam moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode cam stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the mode actuator and the mode cam. The heater-A/C control module learns the mode cam stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. RECIRCULATION DOOR ACTUATOR The recirculation door actuator is a reversible, 12 volt Direct Current (DC), servo motor. The single recirculation door actuator is located on the passenger side end of the heater-A/C housing unit, on the side of the intake air housing. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation door actuator is interchangeable with the actuators for the blend air door(s) and the mode door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the lower intake air housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the recirculation air door. The recirculation door actuator does not require mechanical indexing to the recirculation air door, as it is electronically calibrated by the heater-A/C control module. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the recirculation air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the recirculation air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the recirculation door actuator and the recirculation air door. The heater-A/C control module learns the recirculation air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement REMOVAL The single zone heating and air conditioning system is equipped with a single blend door actuator. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Roll the Instrument Panel Assembly back 3. Remove the HVAC unit from the vehicle. 4. Remove the blend actuators. 5. Remove the drive shaft from the blend door. 6. Remove the upper half of the HVAC housing. 7. Slide the blend air module out of the HVAC housing. INSTALLATION 1. Install the drive shaft to the blend air door. 2. Install the blend actuators to the distribution housing. Tighten the mounting screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector for the blend door actuator to the actuator connector receptacle. 4. Roll the Instrument Panel Assembly back into position 5. Connect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5532 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the silencer from beneath the driver- side end of the instrument panel. 3. Disconnect the HVAC wire harness connector for the mode door actuator from the actuator connector receptacle. 4. Remove the two screws that secure the mode actuator to the distribution housing. 5. Remove the mode actuator from the distribution housing. NOTE: Be sure to hold the mode cam and all mode door links in place. INSTALLATION 1. Position the mode actuator onto the heater/AC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode cam. NOTE: Be sure that the mode door links are positioned in the cam. 2. Install and tighten the two screws that secure the mode door actuator to the distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the HVAC wire harness connector for the mode door actuator to the actuator connector receptacle. 4. Reinstall the silencer under the driver side end of the instrument panel. 5. Reconnect the battery negative cable. 6. Perform the heater-A/C control calibration procedure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5533 Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. It is necessary to roll the Instrument Panel back to gain access to the recirculation door actuator 3. Disconnect the HVAC wire harness connector for the recirculation door actuator from the actuator connector receptacle. 4. Remove the two screws that secure the recirculation door actuator to the intake air housing. 5. Remove the recirculation door actuator from the intake air housing. INSTALLATION 1. Position the recirculation door actuator onto the intake air housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door. 2. Install and tighten the two screws that secure the recirculation door actuator to the lower intake air housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle. 4. Roll the Instrument Panel back into position. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions Air Duct: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Ducts Replacement Air Duct: Service and Repair Defroster Ducts Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the defroster duct to the instrument panel armature. 5. Remove the defroster duct from the instrument panel. INSTALLATION 1. Position the defroster duct to the instrument panel. 2. Install the fasteners that secure the defroster duct to the instrument panel armature. 3. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Ducts Replacement > Page 5539 Air Duct: Service and Repair Floor Distribution Ducts Replacement REMOVAL 1. Disconnect the battery negative cable 2. Remove the two screws that hold the passenger side floor duct to the HVAC housing 3. Remove the duct from the HVAC assembly. 4. Remove the two screws that hold the drivers side floor duct to the HVAC housing. 5. Remove the drivers side duct from the HVAC housing. INSTALLATION 1. Install the drivers side duct to the HVAC housing. Tighten the two screws to 2 Nm (17 in. lbs.). 2. Install the passenger side duct to the drivers side duct and the HVAC housing. Tighten the two screws to 2 Nm (17 in lbs) 3. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Ducts Replacement > Page 5540 Air Duct: Service and Repair Instrument Panel Demister Ducts Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the demister ducts to the instrument panel armature. 5. Disengage the demister ducts from the demister outlets. 6. Remove the demister ducts from the instrument panel. INSTALLATION 1. Position the demister ducts to the instrument panel. 2. Engage the demister ducts to the demister outlets. 3. Install the fasteners that secure the demister ducts to the instrument panel armature. 4. Reinstall the instrument panel into the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Reconnect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Ducts Replacement > Page 5541 Air Duct: Service and Repair Instrument Panel Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the panel ducts to the instrument panel armature. 5. Disengage the panel ducts from the panel outlets. 6. Remove the panel ducts from the instrument panel. INSTALLATION 1. Position the panel ducts to the instrument panel. 2. Engage the panel ducts to the panel outlets. 3. Install the fasteners that secure the panel ducts to the instrument panel armature. 4. Reinstall the instrument panel into the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5545 Ambient Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5546 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR Fig. 10 Ambient Temperature Sensor The ambient air temperature sensor is hardwired to the HVAC control and the HVAC control sends out a J1850 message to the overhead console. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the HVAC control head unit. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the HVAC control head unit. Based upon the resistance in the sensor, the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5547 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the HVAC control. If any portion of the ambient temperature sensor circuit fails or if PCI Bus information is missing, a (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 55 °C (140 °F), or if the sensor circuit is shorted. A (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40 °C (- 40 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing the Compass Mini-Trip Computer. SENSOR TEST 1. Turn the ignition OFF. Disconnect and isolate the battery negative cable. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE - 40 °C (- 40 °F) ................................................................................................................................... .................................................. 336 Kilohms 0 °C (32 °F) .................................................................. ........................................................................................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) ................................................................................................................................................. .......................... 17.99 - 21.81 Kilohms 20 °C (68 °F) ........................................................................ ................................................................................................... 11.37 - 13.61 Kilohms 25 °C (77 °F) .............................................................................................................................................................. ............... 9.12 - 10.86 Kilohms 30 °C (86 °F) ..................................................................................... .......................................................................................... 7.37 - 8.75 Kilohms 40 °C (104 °F) .......... .............................................................................................................................................................. ..... 4.90 - 5.75 Kilohms 55 °C (140 °F) ............................................................................................... ...................................................................................... 2.488 Kilohms The sensor resistance should read between these min/max values. If the resistance values are OK, refer to Sensor Circuit Test. If the resistance values are not OK, replace the sensor. SENSOR CIRCUIT TEST 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the HVAC control harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the HVAC control harness connector. There should be continuity If OK, go to Step 4.If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the HVAC control harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing of the Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5548 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.16 Ambient Temparature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Blower Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Blower Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Blower Motor Control Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5572 Blower Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5573 Blower Motor: Description and Operation The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. The blower motor controls the velocity of air flowing through the heater-A/C housing by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor will only operate when the ignition switch is in the On position, and the heater-A/C blower control switch knob is in any position, except Off. The blower motor receives a fused battery feed through the blower motor relay whenever the ignition switch is in the On position. The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center (PDC). The blower motor control circuit is protected by a fuse in the junction block. Blower motor speed is controlled by regulating the ground path through the heater-A/C mode control switch, the blower motor switch, the blower motor resistor. The blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are each serviced separately Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5574 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For circuit descriptions and diagrams, refer to Air Conditioning/Heater in Wiring Diagrams. Inoperative Possible causes of an inoperative blower motor include: Faulty fuse - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor resistor - Faulty blower motor relay - Faulty voltage reduction relay - Faulty blower motor switch - Faulty heater-A/C mode control switch - Faulty blower motor. Partial Operation Possible causes of the blower motor not operating in all speeds include: Faulty fuse - Faulty blower motor switch - Faulty blower motor resistor - Faulty blower motor relay - Faulty blower motor circuit wiring or wire harness connectors. Vibration Possible causes of blower motor vibration include: Improper blower motor mounting - Improper blower wheel mounting - Blower wheel out of balance or deformed - Blower motor faulty. - Foreign material in blower wheel causing unbalance Noise To verify that the blower is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away possible causes include: Improper blower motor mounting - Improper blower wheel mounting - Blower motor faulty. - Foreign material in blower wheel causing unbalance. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5575 Blower Motor: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect the battery negative cable. 2. Remove the lower right kick panel. 3. Unplug the blower motor electrical connector. 4. Remove the three screws that secure the blower motor and blower wheel assembly to the heater-A/C housing. 5. Pull the blower motor and wheel assembly out of the passenger compartment side of the heater-A/C housing. INSTALLATION 1. Place the blower motor and wheel assembly inside the HVAC housing. 2. Install the three screws that secure the blower motor, air spoiler, and wheel assembly to the heater- A/C housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Plug blower motor connections together. 4. Install lower right kick panel 5. Connect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations The blower motor resistor is mounted to the HVAC unit inside the passenger compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5579 Blower Motor Resistor Block Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5580 Blower Motor Resistor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5581 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR BLOCK The blower motor resistor is mounted to the HVAC unit inside the passenger compartment. It can be accessed from the passenger foot well area. See Blower Motor Resistor in the Removal and Installation for more information. The resistor has multiple resistor circuits each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor circuit to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor circuits. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor circuits, increasing the blower motor speed. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5582 Blower Motor Resistor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5583 Blower Motor Resistor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. From the passenger foot well area, remove the two hex screws used to secure the blower motor resistor. 3. Unplug the front blower motor resistor from the wire harness connector. 4. Remove the front blower motor resistor from the HVAC unit. INSTALLATION 1. Plug the blower motor resistor into the wire harness connector. 2. Install the blower motor resistor to the cowl plenum panel by feeding the resistor and wire harness back through the cowl plenum access hole. 3. Install and tighten the two screws that secure the resistor to the HVAC unit. Tighten the screws to 22 Nm (20 in lbs). 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service Precautions Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service Precautions > Page 5587 Blower Motor Switch: Description and Operation The heater-A/C blower motor is controlled by a five position (OFF plus 4 speeds) rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the blower control switch to the blower motor resistor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service Precautions > Page 5588 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the a/c heater control from the instrument panel. Check for continuity between the ground circuit cavity of the a/c heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3.If not OK, repair the open circuit to ground as required. 3. With the a/c heater control wire harness connector unplugged, place the a/c heater blower control switch knob in any position except the OFF position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the a/c heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the a/c heater control connector and the blower motor resistor as required. If not OK, replace the faulty a/c heater control unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service Precautions > Page 5589 Blower Motor Switch: Service and Repair REMOVAL The blower motor switch is integrated into the HVAC control assembly. 1. If the blower motor switch cannot be repaired or replaced and if damaged the entire HVAC control unit will require replacement. INSTALLATION The rear blower motor switch is not serviceable and is damaged or faulty replacement of the entire HVAC control assembly is required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor Clutch Air Gap .................................................................................................................................... 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5597 A/C Compressor Clutch (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5598 Compressor Clutch: Description and Operation Fig.1 Compressor Clutch - Typical The compressor clutch assembly consists of a stationary electromagnetic coil a rotor bearing and rotor assembly and a clutch plate The electromagnetic coil unit and the rotor bearing and rotor assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is mounted to the compressor shaft and secured with a nut. The compressor clutch assembly provides the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch into contact with the rotor and drives the compressor shaft. When the coil is not energized, the rotor freewheels on the clutch rotor bearing, which is part of the rotor. The compressor clutch and coil are the only serviced parts on the compressor. The compressor clutch engagement is controlled by several components: the a/c heater mode control switch, the a/c loss of charge switch, the a/c pressure transducer, the compressor clutch relay, the evaporator temperature sensor and the Powertrain Control Module (PCM). The PCM may delay compressor clutch engagement for up to 30 seconds. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5599 Compressor Clutch: Testing and Inspection The battery must be fully-charged before performing the following tests. 1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil. 2. With the a/c select button depressed, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle. 3. The compressor clutch coil voltage should read within 0.2 volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within 0.2 volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRB III scan tool and for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: Fuses in the junction block and the Power Distribution Center (PDC) - A/C Heater Control - Compressor Clutch Relay - A/C Pressure Transducer - Evaporator Temperature Sensor - Powertrain Control Module (PCM) 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21 °C (70 °F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the coil is open and should be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In Compressor Clutch: Service and Repair A/C Compressor Clutch Break-In STANDARD PROCEDURE - A/C COMPRESSOR CLUTCH BREAK-IN After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds ON, then five seconds OFF). During this procedure, set the a/c heater control to the recirculation mode (Max-A/C), the blower motor switch to the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5602 Compressor Clutch: Service and Repair A/C Compressor Clutch Replacement REMOVAL The refrigerant system can remain fully-charged during compressor clutch, rotor, or coil replacement. The compressor clutch can be serviced in the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. Refer to Cooling for the procedures. 3. Unplug the compressor clutch coil wire harness connector. Fig.2 Clutch Nut Remove 4. Insert the two pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut. 5. Remove the clutch plate and the clutch shims. Fig.3 External Snap Ring Remove 6. Remove the external front housing snap ring with snap ring pliers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5603 Fig.4 Shaft Protector And Puller 7. Install the lip of the rotor puller (Special Tool C-6141-1 in Kit 6460) into the snap ring groove exposed in Step 6, and install the shaft protector (Special Tool C-6141-2 in Kit 6460). Fig.5 Install Puller Plate 8. Install the puller through-bolts (Special Tool C-6461) through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5604 Fig.6 Clutch Coil Lead Wire Harness 9. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. Fig.7 Clutch Field Coil Snap Ring Remove 10. Remove the snap ring from the compressor hub and remove the clutch field coil. Slide the clutch field coil off of the compressor hub. INSPECTION Examine the friction surfaces of the clutch rotor and the clutch plate for wear. The rotor and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. Remove the felt from the front cover. If the felt is saturated with oil, the shaft seal is leaking and the compressor must be replaced. Check the clutch rotor bearing for roughness or excessive leakage of grease. Replace the rotor and clutch plate, if required. INSTALLATION Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5605 1. Install the clutch field coil and snap ring. 2. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw. Care must be taken not to pinch the lead wire with the retaining clip when tightening the retaining screw. 3. Align the rotor assembly squarely on the front compressor housing hub. Fig.8 Rotor Installer Set 4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460). Fig.9 Rotor Install 5. Place the driver tool assembly into the bearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor bearing inner race. 6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the rotor. 7. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor. 8. Ensure that there is adequate clearance between the lead wire and clutch rotor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5606 9. Install the original clutch shims on the compressor shaft. Fig.10 Clutch Plate Install 10. Install the clutch plate. Use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the clutch plate. 11. Replace the compressor shaft hex nut. Tighten the nut to 15 to 20 Nm (11 to 15 ft. lbs.). Fig.11 Check Clutch Air Gap 12. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.41 to 0.79 millimeter (0.016 to 0.031 inch). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation. NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch. 13. To complete the procedure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5610 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5611 Compressor Clutch Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5612 A/C Compressor Clutch Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5613 Compressor Clutch Relay: Description and Operation A/C COMPRESSOR CLUTCH RELAY The a/c compressor clutch relay is a International Standards Organization (ISO) micro relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the a/c heater control, the a/c loss of charge switch, the a/c pressure transducer and the evaporator fin probe. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5614 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3.If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2.If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4.If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5.If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5615 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.13 Power Distribution Center Location 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover 3. Connect the battery negative cable 4. Test the relay operation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Torque Specifications Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5619 Condenser HVAC: Locations The condenser is located in the air flow in front of the engine cooling radiator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5620 Capacitor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5621 Condenser HVAC: Description and Operation A/C CONDENSER The condenser is located in the air flow in front of the engine cooling radiator The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins, thus causing the refrigerant to change to a liquid state. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5622 Condenser HVAC: Service and Repair REMOVAL CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Fig.5 Condenser Line Fittings 3. Disconnect the refrigerant line fitting that secures the discharge line to the condenser inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the refrigerant line fitting that secures the liquid line to the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 6. Remove the condenser cooling module from the vehicle. INSTALLATION CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. 1. Remove the plugs or tape from the refrigerant line fittings on the liquid line and the condenser outlet. Connect the liquid line to the condenser outlet. Tighten the fitting to 22.59 ± 3.39 Nm (200 ± 30 in. lbs.). 2. Remove the plugs or tape from the refrigerant line fittings on the discharge line and the condenser inlet. Connect the discharge line to the condenser inlet. Tighten the fitting to 22.59 ± 3.39 Nm (200 ± 30 in. lbs.). 3. Check that all of the condenser and radiator air seals are in their proper locations. 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations The a/c heater control is located to the right of the instrument cluster on the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5626 Control Assembly: Diagrams A/C-Heater Control C1 A/C-Heater Control C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5627 Control Assembly: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5628 Control Assembly: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application A/C-Heater Control .............................................................................................................................. ........................................................... 6233137 Heater Control .......................................................... ....................................................................................................................................... 6233137 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5629 Control Assembly: Description and Operation Fig.14 A/C Heater Control A/C HEATER CONTROL The a/c heater control is a completely electronic control head. The a/c heater system uses all electrical controls These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner's manual in the vehicle glove box for more information on the features, use, and suggested operation of these controls. The a/c heater control is located to the right of the instrument cluster on the instrument panel. The a/c heater control contains a rotary-type temperature control knob, a rotary-type mode control knob, a rotary-type blower motor speed knob, and push buttons for a/c compressor and rear window defogger/heated mirror operation. The a/c heater control is fully electronic, contains the logic and control circuits for the HVAC system, and is on the J1850 data bus. The a/c heater control cannot be repaired. If faulty or damaged, the entire unit must be replaced. The illumination lamps are available for service replacement. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5630 Control Assembly: Testing and Inspection Satisfactory heater and air conditioner performance depends upon proper operation and adjustment of all operating controls and refrigeration system components. For circuit descriptions and diagrams, refer to Air Conditioning/Heater in Group 8W - Wiring Diagrams. Use of the DRB-III is required for diagnosis and testing, follow instructions on DRB-III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5631 Control Assembly: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Remove the screws that secure the a/c heater control to the cluster bezel. 4. Remove the a/c heater control from the cluster bezel. 5. Unplug the wire harness connectors from the back of the heater-A/C control. INSTALLATION 1. Plug the wire harness connector into the back of the heater - A/C control. 2. Position the a/c heater control in the instrument panel cluster bezel. 3. Install the fastener screws and tighten to 2.2 Nm (17 ±3 in. lbs.). 4. Install the cluster bezel in the instrument panel 5. Connect the battery negative cable 6. Perform A/C cool down test with DRB III Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications Coupler HVAC: Specifications Intermediate Shaft Coupler Pinch Bolt ......................................................................................................................... 13.5 N.m (10 Ft. Lbs) (120 In. Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 5635 Coupler HVAC: Description and Operation Fig.9 Spring-Lock Coupler - Typical REFRIGERANT LINE COUPLER Spring-lock type refrigerant line couplers are used to connect many of the refrigerant lines and other components to the refrigerant system. These couplers require a special tool for disengaging the two coupler halves. The spring-lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting. When the two coupler halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Two O-rings on the male half of the fitting are used to seal the connection. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. Secondary clips are installed over the two connected coupler halves at the factory for added blowoff protection. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 5636 Coupler HVAC: Service and Repair REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary clip from the spring-lock coupler. Fig.10 Refrigerant Line Spring-Lock Coupler Disconnect 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the springlock coupler cage. 4. Close the two halves of the A/C line disconnect tool around the spring-lock coupler. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring. Once the garter spring is expanded and while still pushing the disconnect tool into the open side of the coupler cage, pull on the refrigerant line attached to the female half of the coupler fitting until the flange on the female fitting is separated from the garter spring and cage on the male fitting within the disconnect tool. NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 6. Open and remove the A/C line disconnect tool from the disconnected spring-lock coupler. 7. Complete the separation of the two halves of the coupler fitting. Inspect the O-ring seals and mating areas do damage. INSTALLATION WARNING: BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Check to ensure that the garter spring is located within the cage of the male coupler fitting, and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupler fitting. 3. Install new O-rings on the male half of the coupler fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak intermittently during vehicle operation. 4. Lubricate the male fitting and O-rings, and the inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female half of the coupler fitting over the male half of the fitting. 6. Push together firmly on the two halves of the coupler fitting until the garter spring in the cage on the male half of the fitting snaps over the flanged end on the female half of the fitting. 7. Ensure that the spring-lock coupler is fully engaged by trying to separate the two coupler halves. This is done by pulling the refrigerant lines on either side of the coupler away from each other. 8. Reinstall the secondary clip over the springlock coupler cage. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5645 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5646 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5647 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5648 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5649 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5650 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5651 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5652 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5653 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5654 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5655 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5656 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5662 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5663 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5664 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5665 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5666 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5667 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5668 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5669 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5670 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5671 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5672 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5673 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5674 Evaporator Core: Locations The evaporator coil is located in the heater-A/C housing, under the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5675 Evaporator Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5676 Evaporator Core: Description and Operation A/C EVAPORATOR The evaporator coil is located in the heater-A/C housing, under the instrument panel. The evaporator coil is positioned in the heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the fixed orifice tube as a low-temperature, low-pressure liquid. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a high-pressure gas when it leaves the evaporator. The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5677 Evaporator Core: Service and Repair WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Remove the heater-A/C housing from the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC, See: Housing Assembly HVAC/Service and Repair 2. Remove the upper housing cover, refer to Heating and Air Conditioning, Housing Assembly HVAC. See: Housing Assembly HVAC/Service and Repair 3. Lift the evaporator coil out of the heater-A/C housing. INSTALLATION NOTE: If the evaporator is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. 1. Insert the evaporator coil into the bottom of the heater-A/C housing 2. Reassemble the heater-A/C housing, refer to Heating and Air Conditioning, Housing Assembly HVAC. See: Housing Assembly HVAC/Service and Repair 3. Install the heater-A/C housing into the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC. See: Housing Assembly HVAC/Service and Repair Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: Customer Interest A/C - Water Leaks Onto Passenger Front Floor NUMBER: 23-010-04 REV. A GROUP: Body DATE: September 9, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND REVISED LABOR OPERATIONS. SUBJECT: Passenger Compartment Floor Water Leak OVERVIEW: This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV sealer. MODELS: 2001-2004 (AN) Dakota **2004 - 2005 (CS) Pacifica** 2001 - 2003 (DN) Durango **2002 - 2005 (KJ) Cherokee (International Markets)** 2001 - 2004 (RS) Caravan, Voyager, Town & Country NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).** SYMPTOM/CONDITION: Water may enter the passenger compartment between the HVAC housing and the bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation from the A/C evaporator can run along the evaporator drain tube and enter the passenger compartment if the seal between the HVAC housing and the bulkhead is not sealed properly. This will result in wet passenger compartment carpet when the air conditioning is operating. DIAGNOSIS: If the symptom exists, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of the opening to seal the joint between the bulkhead and the HVAC gasket and the joint between the drain tube and the HVAC gasket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 5686 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Front Floor NUMBER: 23-010-04 REV. A GROUP: Body DATE: September 9, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND REVISED LABOR OPERATIONS. SUBJECT: Passenger Compartment Floor Water Leak OVERVIEW: This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV sealer. MODELS: 2001-2004 (AN) Dakota **2004 - 2005 (CS) Pacifica** 2001 - 2003 (DN) Durango **2002 - 2005 (KJ) Cherokee (International Markets)** 2001 - 2004 (RS) Caravan, Voyager, Town & Country NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).** SYMPTOM/CONDITION: Water may enter the passenger compartment between the HVAC housing and the bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation from the A/C evaporator can run along the evaporator drain tube and enter the passenger compartment if the seal between the HVAC housing and the bulkhead is not sealed properly. This will result in wet passenger compartment carpet when the air conditioning is operating. DIAGNOSIS: If the symptom exists, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of the opening to seal the joint between the bulkhead and the HVAC gasket and the joint between the drain tube and the HVAC gasket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 5692 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5696 Evaporator Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5697 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the HVAC Control Module. The evaporator temperature sensor is used to switch the A/C compressor clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the HVAC control module. The A/C compressor clutch is switched OFF/ON when the probe temperatures are near 0 °C (32 °F). NOTE: Hysteresis and OFF/ON temperatures vary depending on the blower speed and software algorithm. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor is non-repairable, and must be replaced if found faulty Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5698 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove and isolate the battery negative cable. 2. Remove the access panel from the passenger side of the HVAC housing below the glove box housing to gain access to the evaporator temperature sensor. Fig.17 Evaporator Sensing Probe (typical) 3. Remove the evaporator temperature sensor from the evaporator. 4. Disconnect the evaporator temperature sensor lead wire from the wiring harness. 5. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor to the evaporator. 2. Connect the evaporator temperature sensor lead to the wiring harness. 3. Install the evaporator temperature sensor panel to the HVAC housing. Be sure to install the panel seal if seal is damaged replace as required. 4. Reinstall the battery negative cable to the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations The fixed orifice tube is located near the front end of the rear half of the two-piece liquid line. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 5702 Expansion Valve: Description and Operation Fig.6 Fixed Orifice Tube - Typical A/C ORIFICE TUBE The fixed orifice tube is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. The fixed orifice tube is located near the front end of the rear half of the two-piece liquid line. It is accessed for service by separating the tube fitting that joins the two halves of the liquid line. The inlet end of the fixed orifice tube has a nylon mesh filter screen, which filters the refrigerant and helps to reduce the potential for blockage of the metering orifice by refrigerant system contaminants. The outlet end of the tube has a nylon mesh diffuser screen. The O-rings on the plastic body of the fixed orifice tube seal the tube to the inside of the liquid line and prevent the refrigerant from bypassing the fixed metering orifice. The fixed orifice tube is used to meter the flow of liquid refrigerant into the evaporator coil. The high-pressure liquid refrigerant from the condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the fixed orifice tube. The fixed orifice tube cannot be repaired and, if faulty or plugged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 5703 Expansion Valve: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Disconnect the liquid line refrigerant line fastener at the condenser outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. CAUTION: Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. 4. Remove the front half of the liquid line from the rear half by disconnecting it at the tube fitting. Install plugs in, or tape over all of the opened refrigerant line tube fittings. 5. Remove the fixed orifice tube from the rear half of the liquid line using a pair of needle nose pliers. Note the orientation of the fixed orifice tube for correct reinstallation. INSTALLATION Fig.7 Fixed Orifice Tube - Typical 1. Insert the fixed orifice tube into the rear half of the liquid line. Be certain that it is properly oriented. 2. Remove the tape or plugs from all of the refrigerant line tube fittings. Install a new O-ring on the liquid line tube fitting. Connect and tighten the tube fitting on the front half of the liquid line to the tube fitting on the rear half of the liquid line. 3. Remove the tape or plugs from all of the refrigerant line fittings. Install the front half of the liquid line to the condenser outlet tube. Tighten the fastener to 22.6 ± 3.39 Nm (200 ± 30 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5707 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5708 Heater Core: Description and Operation The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5709 Heater Core: Service and Repair REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Drain to cooling systems. 2. Remove the heater-A/C housing from the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair. See: Housing Assembly HVAC/Service and Repair 3. Disassemble the HVAC housing to access the heater core. 4. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble the heater-A/C housing. 3. Install the heater-A/C housing into the vehicle, refer to Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair. See: Housing Assembly HVAC/Service and Repair 4. Refill the cooling system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 5713 High Pressure Safety Valve HVAC: Description and Operation A/C COMPRESSOR HIGH PRESSURE RELIEF VALVE A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system components, caused by condenser air flow restriction or an overcharge of refrigerant. The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents refrigerant, it does not mean the valve is faulty. The high pressure relief valve is a factory-calibrated unit The valve cannot be adjusted or repaired and must not be removed or otherwise disturbed The valve is only serviced as a part of the compressor assembly. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Lines At Compressor ............................................................................................................................. 23 Nm (17 Ft. Lbs) (200 ± 30 In .Lbs) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 5717 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 5718 Hose/Line HVAC: Description and Operation REFRIGERANT LINES The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut-block style fittings. A stat-O-seal type flat steel gasket with a captured compressible O-ring, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c pressure transducer switch. 4. Remove the fasteners and disconnect the refrigerant line couplers at the condenser and the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the accumulator. Tighten the fasteners to 22 ± 3.38 Nm (200 ± 30 in. lbs.). 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the fastener that secures the refrigerant line support bracket near the compressor. Tighten the mounting screw to 6.77 ± 1.7 Nm (60 ± 15 in. lbs.). 4. Plug in the wire harness connector to the pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5721 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the engine air filter housing. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the liquid line to evaporator coupler. 5. Disconnect the liquid line fastener at the condenser, and refrigerant line coupler at the evaporator. 6. Disengage the two clips that secure the liquid line to the inner fender shield. 7. Remove the liquid line from the vehicle. INSTALLATION High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Install the liquid line in the two clips on the inner fender shield. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator and install the secondary clip. Tighten the fastener at the condenser to 22.6 ± 3.38 Nm (200 ± 30 in. lbs.). 3. If the vehicle is so equipped, reinstall the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel. 4. Reinstall the engine air filter housing. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5722 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c pressure transducer switch. 4. Remove the fasteners and disconnect the refrigerant line couplers at the condenser and the accumulaton. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the accumulator. Tighten the fasteners to 22 ± 3.38 Nm (200 ± 30 in. lbs.). 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the fastener that secures the refrigerant line support bracket near the compressor. Tighten the mounting screw to 6.77 ± 1.7 Nm (60 ± 15 in. lbs.). 4. Plug in the wire harness connector to the pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications Torque Specifications Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 5726 Housing Assembly HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 5727 Housing Assembly HVAC: Description and Operation HVAC HOUSING All vehicles are equipped with a common heater- A/C housing assembly The system combines air conditioning, heating and ventilating capabilities in a single unit housing mounted under the instrument panel. Outside fresh air enters the vehicle through the cowl top opening at the base of the windshield, and passes through a plenum chamber to the heater-A/C system blower housing. Air flow velocity can then be adjusted with the blower motor speed selector switch on the heater-A/C control panel. The air intake openings must be kept free of snow, ice, leaves, and other obstructions for the heater-A/C system to receive a sufficient volume of outside air. It is also important to keep the air intake openings clear of debris because leaf particles and other debris that are small enough to pass through the cowl plenum screen can accumulate within the heater-A/C housing. The closed, warm, damp and dark environment created within the heater-A/C housing is ideal for the growth of certain molds, mildews and other fungi. Any accumulation of decaying plant matter provides an additional food source for fungal spores, which enter the housing with the fresh air. Excess debris, as well as objectionable odors created by decaying plant matter and growing fungi can be discharged into the passenger compartment during heater-A/C system operation. The heater and optional air conditioner are blend- air type systems. In a blend-air system, a blend-air door controls the amount of unconditioned air (or cooled air from the evaporator on models with air conditioning) that is allowed to flow through, or around, the heater core. A temperature control knob on the heater-A/C control panel determines the discharge air temperature. By moving a electric actuator which operates the blend-air door. This allows an almost immediate manual control of the output air temperature of the system. The mode control knob on the heater-only or heater-A/C control panel is used to direct the conditioned air to the selected system outlets. The mode control switches use an electric actuator to control the mode doors. The optional air conditioner for all models is designed for the use of non-CFC, R-134a refrigerant. The air conditioning system has an evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. This air conditioning system uses a fixed orifice tube in the liquid line between the condenser and the evaporator coil to meter refrigerant flow to the evaporator coil. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 5728 Housing Assembly HVAC: Service and Repair REMOVAL HVAC Housing The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the heater core, evaporator coil, blend-air module, various doors and linkages. For HVAC Housing service procedures that involve the removal of instrument panel components, refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Service and Repair. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to Heating and Air Conditioning, Refrigerant, Service and Repair. See: Refrigerant/Service and Repair 4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube, refer to Heating and Air Conditioning, Hose/Line HVAC, Service and Repair. See: Hose/Line HVAC/Service and Repair Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube refer to Heating and Air Conditioning, Hose/Line HVAC, Service and Repair. See: Hose/Line HVAC/Service and Repair Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Drain the engine cooling system. 7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 8. Remove the two screws that retain the hanger strap and air inlet to the plenum. 9. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. HVAC Housing Plenum Adapter WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Remove the heater-A/C housing from the vehicle. 2. Slide the heater-A/C housing plenum adapter all the way to one side of the plenum opening. 3. Pull downwards sharply and firmly on the opposite side of the plenum adapter to disengage the snap feature from the plenum opening. 4. Remove the plenum adapter from the plenum panel. INSTALLATION HVAC Housing Plenum Adapter 1. Install the heater-A/C housing plenum adapter to the plenum panel opening, be certain that the snap features on each side of the adapter are fully engaged with the sides of the plenum panel opening. This must be a water tight connection to prevent leaks. 2. Install the plenum adapter to the plenum panel. 3. Push upwards sharply and firmly on the opposite side of the plenum adapter to disengage the snap feature to the plenum opening. 4. Slide the heater-A/C housing plenum adapter onto the plenum opening. 5. Install the heater-A/C housing to the vehicle. HVAC Housing 1. Position the heater-A/C housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes. 2. Install the screw that secures the air inlet to the plenum. 3. Install and tighten the four nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.). 4. Install the screw that secures the hanger strap to the plenum. 5. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. 6. If the vehicle is not equipped with air conditioning, go to Step 10.If the vehicle is equipped with air conditioning, unplug or remove the tape from the accumulator inlet tube and the evaporator outlet tube fittings. Connect the accumulator inlet tube coupler to the evaporator outlet tube, refer to Hose/Line, Service and Repair. See: Hose/Line HVAC/Service and Repair 7. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube, refer to Hose/Line, Service and Repair. See: Hose/Line HVAC/Service and Repair Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 5729 8. Evacuate the refrigerant system, refer to Hose/Line, Service and Repair. See: Hose/Line HVAC/Service and Repair 9. Charge the refrigerant system refer to Hose/Line, Service and Repair. See: Hose/Line HVAC/Service and Repair 10. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 11. Connect the battery negative cable. 12. Start the engine and check for proper operation of the heating and air conditioning systems. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ....................................................... 32 oz. (0.907 kg) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5734 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 5737 http://www.macsw.org/ Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 5738 Refrigerant: Technician Safety Information WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING AN AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED, BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Page 5739 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Page 5740 Refrigerant: Testing and Inspection If the air conditioning system is not cooling properly, determine if the refrigerant system is fullycharged. If the refrigerant system is low or empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. An electronic leak detector designed for R-134a refrigerant, or a fluorescent R-134a leak detection dye and a black light are recommended for locating and confirming refrigerant system leaks. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. To detect a leak in the refrigerant system with an electronic leak detector, perform one of the following procedures: SYSTEM EMPTY 1. Evacuate the refrigerant system. 2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. With the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 5. To inspect the evaporator for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, and the mode control switch in the recirculation mode. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run with the air conditioning system turned ON for five minutes. 3. With the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, and the mode control switch in the recirculation mode. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery Refrigerant: Service and Repair Refrigerant - Recovery STANDARD PROCEDURE - REFRIGERANT RECOVERY A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 5743 Refrigerant: Service and Repair Refrigerant - Evacuate STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and could damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant system, use the following procedure: 1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold gauge set (if required) to the refrigerant system of the vehicle and recover refrigerant.. 2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn OFF the vacuum pump. a. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. See Refrigerant System Leaks in the Diagnosis and Testing for the procedures. b. If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. 3. Close all of the valves, and turn OFF the charging station vacuum pump. 4. The refrigerant system is now ready to be charged with R-134a refrigerant. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 5744 Refrigerant: Service and Repair Refrigerant - Charge STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system. A 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Total System ........................................................................................................................................ ......................................................... 210 ml (7.1 oz.) Accumulator ......................................................................................................................................... ............................................................. 90 ml (3 oz.) Condenser ........................................................................................................................................... ............................................................... 30 ml (1 oz.) Evaporator ........................................................................................................................................... .............................................................. 60 ml (2 oz.) Compressor ......................................................................................................................................... ..................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5749 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... ............................................................. SP-15 PAG PAG - PolyAlkylene Glycol Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5750 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The SD7H15 compressor used in this vehicle is designed to use an SP-20 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5751 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities STANDARD PROCEDURE - REFRIGERANT OIL LEVEL When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The accumulator, evaporator, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a accumulator, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5756 Low Pressure Sensor / Switch: Locations The a/c loss of charge switch is located on the top of the accumulator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5757 Low Pressure Sensor / Switch: Description and Operation A/C LOSS OF CHARGE SWITCH The a/c loss of charge switch is located on the top of the accumulator. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the a/c compressor clutch. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5758 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the loss of charge switch wire harness connector from the switch on the accumulator fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cycling clutch switch. There should be continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or above, and no continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5759 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the loss of charge switch on the top of the accumulator. 3. Unscrew the loss of charge switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5764 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5765 Compressor Clutch Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5766 A/C Compressor Clutch Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5767 Compressor Clutch Relay: Description and Operation A/C COMPRESSOR CLUTCH RELAY The a/c compressor clutch relay is a International Standards Organization (ISO) micro relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the a/c heater control, the a/c loss of charge switch, the a/c pressure transducer and the evaporator fin probe. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5768 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3.If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2.If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4.If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5.If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5769 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.13 Power Distribution Center Location 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover 3. Connect the battery negative cable 4. Test the relay operation Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5774 Ambient Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5775 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR Fig. 10 Ambient Temperature Sensor The ambient air temperature sensor is hardwired to the HVAC control and the HVAC control sends out a J1850 message to the overhead console. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the HVAC control head unit. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the HVAC control head unit. Based upon the resistance in the sensor, the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5776 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the HVAC control. If any portion of the ambient temperature sensor circuit fails or if PCI Bus information is missing, a (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 55 °C (140 °F), or if the sensor circuit is shorted. A (- -) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40 °C (- 40 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing the Compass Mini-Trip Computer. SENSOR TEST 1. Turn the ignition OFF. Disconnect and isolate the battery negative cable. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE - 40 °C (- 40 °F) ................................................................................................................................... .................................................. 336 Kilohms 0 °C (32 °F) .................................................................. ........................................................................................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) ................................................................................................................................................. .......................... 17.99 - 21.81 Kilohms 20 °C (68 °F) ........................................................................ ................................................................................................... 11.37 - 13.61 Kilohms 25 °C (77 °F) .............................................................................................................................................................. ............... 9.12 - 10.86 Kilohms 30 °C (86 °F) ..................................................................................... .......................................................................................... 7.37 - 8.75 Kilohms 40 °C (104 °F) .......... .............................................................................................................................................................. ..... 4.90 - 5.75 Kilohms 55 °C (140 °F) ............................................................................................... ...................................................................................... 2.488 Kilohms The sensor resistance should read between these min/max values. If the resistance values are OK, refer to Sensor Circuit Test. If the resistance values are not OK, replace the sensor. SENSOR CIRCUIT TEST 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the HVAC control harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the HVAC control harness connector. There should be continuity If OK, go to Step 4.If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the HVAC control harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing of the Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5777 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.16 Ambient Temparature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 5781 Blower Motor Switch: Description and Operation The heater-A/C blower motor is controlled by a five position (OFF plus 4 speeds) rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the blower control switch to the blower motor resistor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 5782 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the a/c heater control from the instrument panel. Check for continuity between the ground circuit cavity of the a/c heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3.If not OK, repair the open circuit to ground as required. 3. With the a/c heater control wire harness connector unplugged, place the a/c heater blower control switch knob in any position except the OFF position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the a/c heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the a/c heater control connector and the blower motor resistor as required. If not OK, replace the faulty a/c heater control unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 5783 Blower Motor Switch: Service and Repair REMOVAL The blower motor switch is integrated into the HVAC control assembly. 1. If the blower motor switch cannot be repaired or replaced and if damaged the entire HVAC control unit will require replacement. INSTALLATION The rear blower motor switch is not serviceable and is damaged or faulty replacement of the entire HVAC control assembly is required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5787 Evaporator Temperature Sensor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5788 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the HVAC Control Module. The evaporator temperature sensor is used to switch the A/C compressor clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the HVAC control module. The A/C compressor clutch is switched OFF/ON when the probe temperatures are near 0 °C (32 °F). NOTE: Hysteresis and OFF/ON temperatures vary depending on the blower speed and software algorithm. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor is non-repairable, and must be replaced if found faulty Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5789 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove and isolate the battery negative cable. 2. Remove the access panel from the passenger side of the HVAC housing below the glove box housing to gain access to the evaporator temperature sensor. Fig.17 Evaporator Sensing Probe (typical) 3. Remove the evaporator temperature sensor from the evaporator. 4. Disconnect the evaporator temperature sensor lead wire from the wiring harness. 5. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor to the evaporator. 2. Connect the evaporator temperature sensor lead to the wiring harness. 3. Install the evaporator temperature sensor panel to the HVAC housing. Be sure to install the panel seal if seal is damaged replace as required. 4. Reinstall the battery negative cable to the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5794 Low Pressure Sensor / Switch: Locations The a/c loss of charge switch is located on the top of the accumulator. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5795 Low Pressure Sensor / Switch: Description and Operation A/C LOSS OF CHARGE SWITCH The a/c loss of charge switch is located on the top of the accumulator. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the a/c compressor clutch. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5796 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the loss of charge switch wire harness connector from the switch on the accumulator fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cycling clutch switch. There should be continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or above, and no continuity with a suction pressure reading of 48-89 kPa (7-13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 5797 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the loss of charge switch on the top of the accumulator. 3. Unscrew the loss of charge switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5801 Service Port HVAC: Description and Operation The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. It is on the suction line between the compressor and the evaporator for the this engine. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring and the steering column assembly must be replaced. On quad cab models, the seat belt tensioners are deployed by the same signal that deploys the driver and passenger airbags and must also be replaced if either front airbag has been deployed. These components are not intended for reuse and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be obvious during a visual inspection. It is also critical that the mounting surfaces and/or mounting bracket for the Airbag Control Module (ACM) be closely inspected and restored to its original condition following any vehicle impact damage. Because the ACM contains the impact sensors that are used by the supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of this component may cause airbags not to deploy when required, or to deploy when not required. All other vehicle components should be closely inspected following any supplemental restraint deployment, but are to be replaced only as required by the extent of the visible damage incurred. CLEANUP PROCEDURE Fig.3 Wear Safety Glasses And Rubber Gloves - Typical Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a supplemental restraint. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: IF YOU EXPERIENCE SKIN IRRITATION DURING CLEANUP, RUN COOL WATER OVER THE AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5807 Fig.4 Vacuum Heater And A/C Outlets - Typical 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: All damaged, faulty, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is faulty or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed supplemental restraints from the vehicle. Refer to the appropriate service removal procedures. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5808 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5813 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations Air Bag: Locations The driver airbag is located in the center of the steering wheel, where it is secured with two screws to the armature of the four-spoke steering wheel. The passenger airbag is located in the instrument panel in front of the front seat passenger seating position, where it is secured to the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5817 Air Bag: Diagrams Driver Airbag Passenger Airbag Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5818 Air Bag: Service Precautions WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIR-BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5819 Air Bag: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Airbag .................................................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5820 Air Bag: Description and Operation Fig.10 Driver Airbag DRIVER AIRBAG The black, injection molded, thermoplastic driver airbag protective trim cover is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel, where it is secured with two screws to the armature of the four-spoke steering wheel. All models have a Dodge Ram logo embossed in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing, inflator, and horn switch unit is secured within an integral receptacle on the back of the trim cover. The four vertical walls of this receptacle have a total of twelve small windows with blocking tabs that are engaged by twelve hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows, and an integral blocking tab in each window keeps each hook properly engaged with the trim cover, locking the cover securely into place. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5821 Fig.11 Horn Switch The resistive membrane-type horn switch is secured within a plastic tray that is inserted in a pocket or pouch sewn onto the airbag cushion retainer strap, between the trim cover and the folded airbag cushion. One horn switch pigtail wire has an eyelet terminal connector that is captured beneath a nut and washer on the upper right inflator mounting stud. The other horn switch pigtail wire is routed between the upper left inflator mounting stud and the inflator, where it is captured by a small plastic retainer that is pushed onto the stud. The airbag used in this model is a Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. A 65 centimeter (25.5 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a conventional non-azide, pyrotechnic-type unit with a flange and four studs that also serves as the airbag cushion retainer and is secured to the stamped metal airbag housing with four nuts. A connector receptacle on the driver airbag inflator connects the inflator initiator to the vehicle electrical system through a yellow-jacketed, two-wire pigtail harness of the clockspring. The driver airbag cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover and the horn switch with tray may be disassembled from the driver airbag unit, and are available for separate service replacement. The driver airbag is deployed by an electrical signal generated by the Airbag Control Module (ACM) through the driver airbag squib circuit to the initiator in the airbag inflator. When the ACM sends the proper electrical signal to the initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch and tray unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through the porous fabric material used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, all potentially hazardous chemicals are burned during an airbag deployment event. The inert gas that is produced when the chemicals are burned is harmless. How- ever, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. PASSENGER AIRBAG The rearward facing surface of the passenger air- bag door above the glove box is the most visible part of the passenger airbag. The airbag used in this model is a Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. The passenger airbag is located in the instrument panel in front of the front seat passenger seating position, where it is secured to the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5822 instrument panel. Concealed beneath the passenger airbag door are the folded airbag cushion, the airbag retainer or housing, and the airbag inflator. The airbag inflator is a hybrid-type unit that is secured to and sealed within the airbag housing along with the folded airbag cushion. The airbag housing is constructed of a long U-shaped aluminum extrusion with two stamped steel end plates. Two tabs that extend from the bottom of the extrusion serve as the rear mounting brackets, while an angled foot on the bottom of each end plate serve as the front mounting brackets. The front brackets are secured with screws to the instrument panel armature above the glove box, while the rear brackets are secured with screws to the upper glove box opening reinforcement. A yellow connector on the end of a short, two-wire pigtail harness connects the passenger airbag inflator to the vehicle electrical system. The molded plastic passenger airbag door has a predetermined horizontal breakout line near its center which is concealed beneath its decorative outer surface. Return flanges near the top and bottom of the airbag door feature windows that are engaged on hook formations at the top and bottom of the airbag housing. Three tabs extend downward from the lower return flange and are secured with the same screws that secure the glove box module to the upper glove box opening reinforcement. Five molded snap features along the top of the airbag door above the upper return flange snap into receptacles located in the instrument panel base trim just below the instrument panel top cover. Following a passenger airbag deployment, the passenger airbag and airbag door unit must be replaced. The passenger airbag cannot be repaired, and must be replaced if faulty or in any way damaged. The passenger airbag door is serviced only as a unit with the passenger airbag. The passenger airbag is deployed by an electrical signal generated by the Airbag Control Module (ACM) through the passenger airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. When the ACM sends the proper electrical signal to the airbag inflator, the electrical energy generates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce the pressure necessary to rupture a containment disk in the argon gas canister. The inflator and argon gas canister are sealed to the airbag cushion so that all of the released argon gas is directed into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at the breakout line and the two halves of the door will pivot out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the argon gas through vents on the instrument panel side of the airbag cushion. Some of the chemicals used to create the pressure to burst the argon gas containment disk are considered hazardous in their solid state, before they are burned, but they are securely sealed within the airbag inflator. However, the gas that is produced when the chemicals are burned is harmless. A small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noticed, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician immediately. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag Removal and Installation REMOVAL The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS - STANDARD PROCEDURE HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the driver airbag has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the airbag from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - HEN REMOVING A DEPLOYED AIR-BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. Fig. 12 Driver Airbag Remove/Install 2. From the underside of the steering wheel, remove the two screws that secure the driver airbag to the steering wheel armature. 3. Pull the driver airbag away from the steering wheel far enough to access the two wire harness connectors at the back of the airbag. 4. Disconnect the steering wheel wire harness connector for the horn switch from the horn switch feed pigtail wire connector, which is located at the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5825 back of the driver airbag. CAUTION: Do not pull on the clockspring pigtail wire to disengage the connector from the driver air- bag inflator connector receptacle. 5. The clockspring driver airbag pigtail wire connector is a tight snap-fit into the airbag inflator connector receptacle, which is located at the back of the driver airbag. Firmly grasp and pull or gently pry on the clockspring driver airbag wire harness connector to disconnect it from the airbag inflator connector receptacle. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring and the steering column must be replaced. (Refer to RESTRAINTS/ CLOCKSPRING REMOVAL). INSTALLATION The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS - STANDARD PROCEDURE HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the driver airbag has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the airbag from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Assemble the driver airbag trim cover onto the airbag housing. (Refer to RESTRAINTS/ RIVER AIRBAG - ASSEMBLY). 2. When installing the driver airbag, reconnect the clock spring driver airbag pigtail wire connector to the airbag inflator connector receptacle by pressing straight in on the connector. You can be certain that the connector is fully engaged by listening carefully for a distinct, audible click as the connector snaps into place. 3. Reconnect the steering wheel wire harness connector for the horn switch to the horn switch feed pigtail wire connector, which is located at the back of the driver airbag. 4. Carefully position the driver airbag in the steering wheel. Be certain that the clock spring pigtail wire and steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 Nm (90 in. lbs.). 6. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component (Refer to RESTRAINTS STANDARD PROCEDURE VERIFICATION TEST) Disassembly DISASSEMBLY The following procedures can be used to replace the driver airbag trim cover or the horn switch and tray unit. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover, and horn switch must be replaced as a unit. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR-BAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5826 2. Remove the driver airbag from the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG REMOVAL). 3. Using hand pressure, press the airbag housing down into the receptacle on the back of the driver airbag trim cover. 4. Carefully pry back the walls of the driver airbag receptacle on the back of the trim cover to release each of the twelve windows of the trim cover receptacle from the twelve hook formations on the perimeter of the airbag housing. 5. Remove the housing, inflator, cushion, and horn switch as a unit from the driver airbag trim cover receptacle. 6. Gently pry off the plastic wire retainer that captures the horn switch feed pigtail wire between the upper right inflator stud and the inflator on the back of the driver airbag housing. 7. Remove the nut and washer that secures the horn switch ground pigtail wire eyelet terminal to the upper left inflator stud on the back of the driver airbag housing. 8. Remove the horn switch ground pigtail wire eyelet terminal from the upper left inflator stud on the back of the driver airbag housing. 9. Slide the horn switch and tray unit all the way to one side of the pouch on the driver airbag cushion retainer strap to disengage one of the retaining tabs on the tray from one of the slits located in each side of the pouch. Fig.13 Horn Switch Remove/Install 10. Remove the horn switch and tray as a unit from the pouch on the driver airbag cushion retainer strap. Assembly The following procedures can be used to replace the driver airbag trim cover or the horn switch and tray unit. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover, and horn switch must be replaced as a unit. WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR- BAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5827 Fig.14 Horn Switch Installed 1. Install the horn switch and tray unit into the pouch on the driver airbag cushion retainer strap. Be certain that the tray is facing the airbag cushion, that the horn switch membrane is facing the airbag trim cover, that the horn switch feed pigtail wire is on the right, that the horn switch ground pigtail wire is on the left, and that the retaining tabs on the tray are each engaged in one of the slits located in each side of the pouch 2. Route the horn switch ground pigtail wire through the clearance notch between the two upper left hooks on the driver airbag housing. Install the eyelet terminal over the upper left inflator stud and engage the terminal under the anti-rotation tab directly above the stud on the back of the driver air-bag housing. 3. Install and tighten the nut and washer that secure the horn switch ground pigtail wire eyelet terminal to the upper left inflator stud on the back of the driver airbag housing. Tighten the nut to 7 Nm (65 in. lbs.). 4. Route the horn switch feed pigtail wire through the clearance notch between the two upper right hooks and between the upper right inflator stud and the inflator on the back of the driver airbag housing. 5. Using hand pressure, press the plastic wire retainer onto the upper right inflator stud to capture the horn switch feed pigtail wire between the stud and the inflator on the back of the driver airbag housing. 6. Carefully position the driver airbag into the receptacle on the back of the trim cover. Be certain that the horn switch feed and ground pigtail wires remain properly routed through the clearance notches at the top of the airbag housing and are not pinched between the airbag housing and the walls of the trim cover receptacle. 7. Work around the perimeter of the unit engaging each of the twelve hooks on the driver airbag housing through the windows in the walls of the trim cover receptacle. 8. After each of the twelve hooks on the driver airbag housing has been engaged in a window of the trim cover receptacle, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5828 Fig. 15 Driver Airbag Trim Cover Side Blocking Tabs 9. After all of the windows in the walls of the trim cover receptacle have been fully seated in the cradles of the hooks on the airbag housing, push the blocking tabs of the two windows on the right and left side walls of the trim cover receptacle inward so that they are oriented behind the airbag housing hooks, as shown in. Fig. 16 Driver Airbag Trim Cover Upper & Lower Blocking Tabs 10. Inspect the airbag housing hooks in the windows of the upper and lower walls of the trim cover receptacle to be certain they are fully engaged and that the blocking tabs for these windows are oriented over the tops of the hooks, as shown in. 11. Reinstall the driver airbag onto the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5829 Air Bag: Service and Repair Passenger Airbag REMOVAL The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS - STANDARD PROCEDURE HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the passenger airbag has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the airbag from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the glove box module from the instrument panel. 3. Remove the radio from the instrument panel (Refer to AUDIO/RADIO - REMOVAL). Fig.21 Passenger Airbag Connector 4. Reach through the radio opening in the instrument panel to access and disconnect the instrument panel wire harness connector for the passenger air- bag from the passenger airbag pigtail wire connector on the instrument panel armature to the left of the glove box opening. 5. Disengage the passenger airbag pigtail wire connector retainers from the instrument panel armature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5830 Fig.22 Passenger Airbag Mounting 6. Working through the glove box opening, remove the two screws that secure the passenger airbag front brackets to the instrument panel armature. 7. Remove the two screws that secure the passenger airbag rear brackets to the glove box opening upper reinforcement. 8. Using a trim stick or another suitable wide flat-bladed tool, gently pry the top of the passenger airbag door away from the instrument panel far enough to disengage the five snap features on the airbag door from their receptacles in the instrument panel. 9. Remove the passenger airbag and airbag door from the instrument panel as a unit. INSTALLATION The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS - STANDARD PROCEDURE HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the passenger airbag has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the airbag from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG DOORS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the passenger airbag into the instrument panel. 2. Align the five snap features on the upper edge of the passenger airbag door with the receptacles in the instrument panel top cover. 3. Using hand pressure, press firmly on the passenger airbag door over each of the snap feature locations until each of them is fully engaged in its receptacle. 4. Install and tighten the two screws that secure the passenger airbag rear brackets to the glove box opening upper reinforcement. Tighten the screws to 9 Nm (80 in. lbs.). 5. Working through the glove box opening, install and tighten the two screws that secure the passenger airbag front brackets to the instrument panel armature. Tighten the screws to 9 Nm (80 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5831 6. Reach through the radio opening in the instrument panel to access and reconnect the instrument panel wire harness connector for the passenger airbag to the passenger airbag pigtail wire connector. Be certain that the passenger airbag pigtail wire connector is fully engaged with and latched to the instrument panel wire harness connector. 7. Engage the passenger airbag pigtail wire connector retainers in the mounting holes provided on the instrument panel armature. 8. Reinstall the radio into the instrument panel (Refer to AUDIO/RADIO - INSTALLATION). 9. Reinstall the glove box module onto the instrument panel. 10. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5835 Airbag Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5836 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5837 Air Bag Control Module: Description and Operation AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. There are no external impact sensors. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) and Central Timer Module (CTM) from the ACM via the PCI bus. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn on the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For models equipped with the passenger airbag ON/OFF switch (all except Quad Cab), the ACM receives a resistor multiplexed input from this switch and provides a control output for the OFF indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag ON/OFF switch is set to the OFF position, the ACM turns on the passenger airbag ON/OFF switch OFF indicator and will internally disable the passenger airbag from being deployed if an impact is detected that is sufficient for an airbag deployment. The ACM also turns ON the ON/OFF switch OFF indicator for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. Following the bulb test, the ACM controls the status of the OFF indicator based upon the resistance of the input from the ON/OFF switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag ON/OFF switch circuits, and will turn ON the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits, on a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to 1 second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags and, on quad cab models, the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5838 test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5839 Air Bag Control Module: Service and Repair REMOVAL WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5840 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5844 Passenger Airbag ON/OFF Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information Air Bag Deactivation Switch: Customer Safety Information WARNING - ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. - IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information > Page 5847 Air Bag Deactivation Switch: Technician Safety Information WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 5848 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG ON/OFF SWITCH The passenger airbag ON/OFF switch is standard equipment on all versions of this model except quad cab. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate and nomenclature, the key cylinder actuator, and a small round lens with the text "OFF" imprinted on it. The "ON" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel cluster 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 face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel cluster 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 of the instrument panel wire harness. The harness take out is equipped with a molded plastic connector insulator that 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 faulty or damaged, the switch must be replaced. 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. The ignition key is the only key or object that should ever be inserted into 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 side airbag ON/OFF switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, and 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 indicator), 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. NOTE: Do not turn the ON/OFF switch with the ignition on. 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 Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected and provide circuit diagnostics. The ON/OFF switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the ON/OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code, the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. When the passenger airbag ON/OFF switch is in the OFF position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the OFF indicator of the switch. The ACM will also illuminate the OFF indicator of the switch for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. The ACM will also store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag ON/OFF switch or indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag ON/OFF switch or the ACM, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 5849 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the cluster bezel from the instrument panel. Fig.23 Passenger Airbag On/Off Switch 3. Remove the three screws that secure the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 4. Remove the passenger airbag ON/OFF switch and face plate from the cluster bezel as a unit. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 2. Install and tighten the three screws that secure the passenger airbag ON/OFF switch face plate to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the cluster bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS STANDARD PROCEDURE VERIFICATION TEST) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Clockspring Assembly / Spiral Cable: Locations The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5853 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Premium Radio) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5854 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5855 Clockspring Assembly / Spiral Cable: Description and Operation Fig. 7 Clockspring And Multi-Function Switch The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case with a stubby tail that hangs below the steering column and contains two connector receptacles that face toward the instrument panel. Within the plastic housing is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, two large flats, an engagement dowel with a yellow rubber boot, a short pigtail wire with connector, and two connector receptacles that face toward the steering wheel. The lower surface of the rotor hub has a molded plastic turn signal cancel cam with two lobes that is keyed to the rotor and is secured there with four integral snap features. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wire and connector receptacles on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped precentered and with a locking pin that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment, but the locking pin must be removed from the clockspring after it is installed on the steering column. (Refer to RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE CLOCKSPRING CENTERING). The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this model the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate noise. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. The yellow sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components and must be re-centered following completion of the service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be disengaged until the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5856 clockspring has been installed on the steering column. If the locking pin is removed or damaged before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. (Refer to RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE CLOCKSPRING CENTERING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5857 Clockspring Assembly / Spiral Cable: Adjustments STANDARD PROCEDURE - CLOCKSPRING CENTERING The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape. Fig. 7 Clockspring And Multi-Function Switch However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change position relative to the other steering components. The clockspring must then be re-centered following completion of such service or the clockspring tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. (Refer to RESTRAINTS/ CLOCKSPRING - REMOVAL). 3. Rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot should end up at the bottom, and the arrows on the clockspring rotor and case should be in alignment. The clockspring is now centered. 5. The front wheels should still be in the straight- ahead position. Reinstall the clockspring onto the steering column. (Refer to RESTRAINTS/CLOCKSPRING - INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5858 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the driver airbag from the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG - REMOVAL). 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. 4. Remove the screw that secures the steering wheel armature to the steering column upper shaft, which is located within the hub cavity of the steering wheel. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Pull the steering wheel off of the steering column upper shaft spline using a steering wheel puller (Special Tool C-3428-B). 6. Remove the steering column opening cover from the instrument panel. 7. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 8. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 9. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 10. Remove the upper shroud from the lower shroud. 11. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors for the clockspring from the lower clockspring connector receptacles. Fig. 7 Clockspring And Multi-Function Switch 14. Remove the two screws that secure the clockspring to the multi-function switch mounting housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5859 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. (Refer to RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE - CLOCKSPRING CENTERING). INSTALLATION The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. (Refer to RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE - CLOCKSPRING CENTERING). Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. Carefully slide the centered clockspring down over the steering column upper shaft until the hole in the locating tab at the eleven O'clock position on the clockspring case is engaged over the locating pin on the multi-function switch mounting housing. 2. Install and tighten the two screws that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors for the clockspring to the lower clockspring connector receptacles. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reinstall the steering wheel onto the steering column upper shaft. Be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. Pull the upper clockspring pigtail wire through the upper hole between the steering wheel back trim cover and the steering wheel armature. 12. Install and tighten the screw that secures the steering wheel to the steering column upper shaft. Tighten the screw to 61 Nm (45 ft. lbs.). Be certain not to pinch the clockspring pigtail wire or the steering wheel wire harness between the steering wheel and the screw. 13. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 14. Reinstall the driver airbag onto the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Malfunction Lamp / Indicator: Locations The airbag indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 5863 Malfunction Lamp / Indicator: Description and Operation AIRBAG INDICATOR An airbag indicator is standard equipment on all instrument clusters However, on vehicles not equipped with airbags, this indicator is electronically disabled. The airbag indicator is located in the Information Center area of the instrument cluster, to the right of center. The airbag indicator consists of a stencil-like cutout of the word "AIRBAG" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "AIRBAG" text to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The air- bag indicator is serviced as a unit with the instrument cluster. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Airbag Control Module (ACM) over the Programmable Communications Interface (PCI) data bus. The airbag indicator Light Emitting Diode (LED) 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 airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the airbag indicator is illuminated for about seven seconds. The first two seconds is the cluster bulb test function, and the remainder is the ACM bulb test function. - ACM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the ACM, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-OFF message from the ACM, whichever is longer. - Communication Error - If the cluster receives no airbag messages for three consecutive seconds, the airbag indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the ACM. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The actuator test illumination of the airbag indicator is a function of the instrument cluster. The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ACM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the ACM sends a lamp-ON message after the bulb test, it indicates that the ACM has detected a system malfunction and/or that the air- bags may not deploy when required, or may deploy when not required. The ACM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ACM of the condition. The ACM will store a DTC, and the cluster will flash the seat belt indicator ON and OFF as a backup to notify the vehicle operator. For proper diagnosis of the airbag system, the ACM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the airbag indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5868 Airbag Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5869 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5870 Air Bag Control Module: Description and Operation AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. There are no external impact sensors. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) and Central Timer Module (CTM) from the ACM via the PCI bus. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn on the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For models equipped with the passenger airbag ON/OFF switch (all except Quad Cab), the ACM receives a resistor multiplexed input from this switch and provides a control output for the OFF indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag ON/OFF switch is set to the OFF position, the ACM turns on the passenger airbag ON/OFF switch OFF indicator and will internally disable the passenger airbag from being deployed if an impact is detected that is sufficient for an airbag deployment. The ACM also turns ON the ON/OFF switch OFF indicator for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. Following the bulb test, the ACM controls the status of the OFF indicator based upon the resistance of the input from the ON/OFF switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag ON/OFF switch circuits, and will turn ON the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits, on a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to 1 second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags and, on quad cab models, the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5871 test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5872 Air Bag Control Module: Service and Repair REMOVAL WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5873 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5878 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions Child Seat Tether Attachment: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 5883 Child Seat Tether Attachment: Service and Repair REMOVAL Standard cab models have two child tether straps secured near the top of the cab back panel. Club cab and quad cab models have three child tether straps secured near the top of the cab back panel. WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Fig.6 Child Tether Straps 1. Remove the screw that secures the child tether strap (2 used on standard cab, 3 used on club/quad cab) to the cab back panel. 2. Remove the child tether strap from the cab back panel. INSTALLATION Standard cab models have two child tether straps secured near the top of the cab back panel. Club cab and quad cab models have three child tether straps secured near the top of the cab back panel. WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the child tether strap onto the cab back panel. 2. Install and tighten the screw that secures the child tether strap onto the cab back panel. Tighten the screw to 13.5 N m (120 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions Seat Belt: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat Seat Belt: Service and Repair Seat Belt and Retractor - Front Seat REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Move the front seats to their most forward position for easiest access to the lower seat belt anchor plate, the retractor, and the B-pillar. 2. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Lift the cover on the lower seat belt anchor plate far enough to access the screw that secures the anchor plate to the front seat adjuster. Fig.17 Front Seat Belt Lower Anchor 4. Remove the screw that secures the lower seat belt anchor plate to the seat adjuster. 5. Unsnap and remove the front shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 5889 Fig.18 Front Shoulder Belt & Refractor - Quad Cab 6. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 7. Remove the shoulder belt turning loop from the height adjuster. 8. Remove the trim from the B-pillar. 9. Remove the two screws that secure the seat belt web guide to the B-pillar above the retractor. 10. Disconnect the seat belt tensioner pigtail wire connector from the body wire harness connector. 11. On the driver side only, disconnect the seat belt switch pigtail wire connector from the body wire harness connector. 12. Remove the screw that secures the retractor to the B-pillar. 13. Remove the front shoulder belt and retractor from the B-pillar. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Be certain that the retractor shield is properly installed in the B-pillar and in good condition before installing the retractor. 2. Position the retractor into the B-pillar. 3. Install and tighten the screw that secures the retractor to the B-pillar. Tighten tile screw to 40 Nm (29 ft. lbs.). 4. Reconnect tile seat belt tensioner pigtail wire connector to the body wire harness connector. 5. On the driver side only, reconnect the seat belt switch pigtail wire connector to the body wire harness connector. 6. Position the seat belt web guide to the B-pillar above the retractor. 7. Install and tighten the two screws that secure the seat belt web guide to the B-pillar. Tighten the screws to 2 Nm (17 in. lbs.). 8. Reinstall the trim onto the B-pillar. 9. Position tile shoulder belt turning loop onto the height adjuster. 10. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 11. Snap the trim cover over the front shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. 12. Position the lower seat belt anchor plate to the seat adjuster. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 5890 13. Install and tighten the screw that secures the lower seat belt anchor plate to the seat adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 14. Reposition the cover over the lower seat belt anchor plate to conceal the screw that secures the anchor plate to the front seat adjuster. 15. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 5891 Seat Belt: Service and Repair Seat Belt and Retractor - Rear Seat REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the rear shoulder belt turning loop cover to access the screw that secures the turning loop to the C-pillar. Fig.25 Rear Seat Belt & Retractor - Quad Cab 2. Remove the screw that secures the shoulder belt turning loop to the C-pillar. 3. Remove the shoulder belt turning loop from the C-pillar. 4. Remove the trim from the C-pillar. 5. Remove the screw that secures the lower seat belt anchor plate to the C-pillar. 6. Remove the lower seat belt anchor plate from the C-pillar. 7. Remove the screw that secures the retractor to the C-pillar. 8. Remove the rear shoulder belt and retractor from the C-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 5892 1. Position the retractor onto the C-pillar. 2. Install and tighten the screw that secures the retractor to the C-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 3. Position the lower seat belt anchor plate onto the C-pillar. 4. Install and tighten the screw that secures the lower seat belt anchor plate to the C-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 5. Reinstall the trim onto the quarter inner panel (club cab) or the C-pillar (quad cab). 6. Position the shoulder belt turning loop onto the C-pillar. 7. Install and tighten the screw that secures the shoulder belt turning loop to the C-pillar. Tighten the screw to 30 Nm (22 ft. lbs.). 8. Snap the trim cover over the rear shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the C-pillar. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions Seat Belt Buckle: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat Seat Belt Buckle: Service and Repair Seat Belt Buckle - Front Seat REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. If the vehicle is so equipped, remove the console from the floor panel transmission tunnel. 2. If the vehicle is so equipped, remove the bench seat from the passenger compartment. 3. If the vehicle is so equipped, remove the center seat from the passenger compartment. Fig.20 Front Seat Belt Buckle - Typical 4. Remove the screw that secures the front seat belt buckle unit to the seat adjuster. 5. Remove the front seat belt buckle from the seat adjuster. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the front seat belt buckle to the seat adjuster. 2. Install and tighten the screw that secures the front seat belt buckle unit to the seat adjuster. Tighten the screw to 23 Nm (17 ft. lbs.). The buckle should be free to pivot slightly fore and aft after the screw is tightened. 3. If the vehicle is so equipped, reinstall the center seat into the passenger compartment. 4. If the vehicle is so equipped, reinstall the bench seat into the passenger compartment. 5. If the vehicle is so equipped, reinstall the console onto the floor panel transmission tunnel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 5898 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Rear Seat REMOVAL Club cab and quad cab models both have a combined rear seat buckle/buckle unit on the right side of the vehicle that is secured to the rear floor panel beneath the rear seat cushion. Club cab models have a combined rear seat lap belt/buckle unit on the left side of the vehicle that is secured to the rear floor panel beneath the rear seat cushion. The left side of the quad cab models has a rear lap belt unit that is secured to a stud on the left center rear seat riser bracket, and a rear buckle unit that is secured to the rear of the left seat cushion frame. WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Rear Seat Buckle/buckle Unit (CLUB OR QUAD CAB) & Lap Belt/buckle Unit (CLUB CAB ONLY) 1. Remove the rear seat from the rear floor panel (club cab) or fold up the rear seat cushion (quad cab). Fig.26 Rear Seat Belts - Club Cab 2. Remove the screw that secures the anchor plate of the rear seat buckle/buckle unit (right side club cab or quad cab) or lap belt/buckle unit (left side - club cab only) to the rear floor panel. 3. Remove the rear seat buckle/buckle unit (right side) or lap belt/buckle unit (left side) from the rear floor panel. Rear Seat Lap Belt Unit - Left Side - QUAD CAB ONLY 1. Fold up the rear seat cushions against the rear seat back. 2. Remove the nut that secures the rear seat lap belt anchor plate to the stud on the inboard side of the left center rear seat riser bracket. 3. Remove the rear seat lap belt unit from the inboard side of the left center rear seat riser bracket. Rear Seat Buckle Unit - Left Side - QUAD CAB ONLY 1. Fold up the rear seat cushions against the rear seat back. 2. Remove the screw that secures the rear seat belt buckle anchor plate to the rear of the left seat cushion frame. 3. Remove the rear seat belt buckle unit from the rear of the left seat cushion frame. INSTALLATION Club cab and quad cab models both have a combined rear seat buckle/buckle unit on the right side of the vehicle that is secured to the rear floor panel beneath the rear seat cushion. Club cab models have a combined rear seat lap belt/buckle unit on the left side of the vehicle that is secured to the rear floor panel beneath the rear seat cushion. The left side of the quad cab models has a rear lap belt unit that is secured to a stud on the left center rear seat riser bracket, and a rear buckle unit that is secured to the rear of the left seat cushion frame. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 5899 WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Rear Seat Buckle/buckle Unit (CLUB OR QUAD CAB) & Lap Belt/buckle Unit (CLUB CAB ONLY) 1. Position the rear seat buckle/buckle unit (right side) or lap belt/buckle unit (left side) onto the rear floor panel. 2. Install and tighten the screw that secures the anchor plate of the rear seat buckle/buckle unit (right side - club cab or quad cab) or lap belt/buckle unit (left side - club cab only) to the rear floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 3. Reinstall the rear seat onto the rear floor panel (club cab) or fold down the rear seat cushion (quad cab). Rear Seat Lap Belt Unit - Left Side - QUAD CAB ONLY 1. Position the rear seat lap belt unit onto the stud on the inboard side of the left center rear seat riser bracket. 2. Install and tighten the nut that secures the rear seat lap belt anchor plate to the stud on the inboard side of the left center rear seat riser bracket. Tighten the nut to 40 Nm (29 ft. lbs.). 3. Fold down the rear seat cushions. Rear Seat Buckle Unit - Left Side - QUAD CAB ONLY 1. Position the rear seat belt buckle unit onto the rear of the left seat cushion frame. 2. Install and tighten the screw that secures the rear seat belt buckle anchor plate to the rear of the left seat cushion frame. Tighten the screw to 40 Nm (29 ft lbs). 3. Fold down the rear seat cushions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5903 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5904 Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole single throw, plunger actuated, momentary switch Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5905 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions Seat Belt Height Adjuster: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions > Page 5909 Seat Belt Height Adjuster: Service and Repair REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap the seat belt turning loop cover to expose the anchor screw that secures the turning loop to the height adjuster. Fig.14 Shoulder Belt Height Adjuster Knob 2. Using the head of the turning loop anchor screw as a fulcrum, carefully pry the knob from the height adjuster lever with a suitable trim tool. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Snap the seat belt turning loop cover back into place over the anchor screw that secures the turning loop to the adjuster. 2. Position the height adjuster knob to the seat belt turning loop height adjuster lever. 3. Using hand pressure, push the knob firmly and evenly onto the lever until it is hilly engaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations Seat Belt Reminder Lamp: Locations The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 5913 Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Seat Belt .............................................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 5914 Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator Light Emitting Diode (LED) 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 seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit, the indicator will be illuminated as a seatbelt reminder for about seven seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), then flash the seatbelt indicator ON and OFF. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch input to the instrument cluster circuitry can be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions Seat Belt Retractor: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front REMOVAL The following procedure is for replacement of a faulty or damaged front seat belt and retractor, which includes a seat belt tensioner on quad cab models. If a front seat belt or retractor on a quad cab model is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS STANDARD PROCEDURE - HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the front seat belt and retractor from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Move the front seats to their most forward position for easiest access to the lower seat belt anchor plate, the retractor, and the B-pillar. 2. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. Fig.17 Front Seat Belt Lower Anchor 3. Lift the cover on the lower seat belt anchor plate far enough to access the screw that secures the anchor plate to the front seat adjuster. 4. Remove the screw that secures the lower seat belt anchor plate to the seat adjuster. 5. Unsnap and remove the front shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5920 Fig.18 Front Shoulder Belt & Retractor - Quad Cab 6. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 7. Remove the shoulder belt turning loop from the height adjuster. 8. Remove the trim from the B-pillar. 9. Remove the two screws that secure the seat belt web guide to the B-pillar above the retractor. 10. Disconnect the seat belt tensioner pigtail wire connector from the body wire harness connector. 11. On the driver side only, disconnect the seat belt switch pigtail wire connector from the body wire harness connector. 12. Remove the screw that secures the retractor to the B-pillar. 13. Remove the front shoulder belt and retractor from the B-pillar. INSTALLATION The following procedure is for replacement of a faulty or damaged front seat belt and retractor, which includes a seat belt tensioner on quad cab models. If a front seat belt or retractor on a quad cab model is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed passive restraints. (Refer to RESTRAINTS STANDARD PROCEDURE - HANDLING NON-DEPLOYED PASSIVE RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a passive restraint deployment before removing the front seat belt and retractor from the vehicle. (Refer to RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Be certain that the retractor shield is properly installed in the B-pillar and in good condition before installing the retractor. 2. Position the retractor into the B-pillar. 3. Install and tighten the screw that secures the retractor to the B-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Reconnect the seat belt tensioner pigtail wire connector to the body wire harness connector. 5. On the driver side only, reconnect the seat belt switch pigtail wire connector to the body wire harness connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5921 6. Position the seat belt web guide to the B-pillar above the retractor. 7. Install and tighten the two screws that secure the seat belt web guide to the B-pillar. Tighten the screws to 2 Nm (17 in. lbs.). 8. Reinstall the trim onto the B-pillar. 9. Position the shoulder belt turning loop onto the height adjuster. 10. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 11. Snap the trim cover over the front shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. 12. Position the lower seat belt anchor plate to the seat adjuster. 13. Install and tighten the screw that secures the lower seat belt anchor plate to the seat adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 14. Reposition the cover over the lower seat belt anchor plate to conceal the screw that secures the anchor plate to the front seat adjuster. 15. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5922 Seat Belt Retractor: Service and Repair Rear REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the rear shoulder belt turning loop cover to access the screw that secures the turning loop to the quarter inner panel (club cab) or the C-pillar (quad cab). Fig.24 Rear Seat Belt & Refractor - Club Cab Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5923 Fig.25 Rear Seat Belt & Retractor - Quad Cab 2. Remove the screw that secures the shoulder belt turning loop to the quarter inner panel (club cab) or the C-pillar (quad cab). 3. Remove the shoulder belt turning loop from the quarter inner panel (club cab) or the C-pillar (quad cab). 4. Remove the trim from the quarter inner panel (club cab). 5. Remove the screw that secures the lower seat belt anchor plate to the quarter inner panel (club cab) or the C-pillar (quad cab). 6. Remove the lower seat belt anchor plate from the quarter inner panel (club cab) or the C-pillar (quad cab). 7. Remove the screw that secures the retractor to the quarter inner panel (club cab) or the C-pillar (quad cab). 8. Remove the rear shoulder belt and retractor from the quarter inner panel (club cab) or the C-pillar (quad cab). INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PART LISTED IN THE MOPAR PARTS CATALOG. 1. Position the retractor onto the quarter inner panel (club cab) or the C-pillar (quad cab). 2. Install and tighten the screw that secures the retractor to the quarter inner panel (club cab) or the C-pillar (quad cab). Tighten the screw to 40 Nm (29 ft. lbs.). 3. Position the lower seat belt anchor plate onto the quarter inner panel (club cab) or the C-pillar (quad cab). 4. Install and tighten the screw that secures the lower seat belt anchor plate to the quarter inner panel (club cab) or the C-pillar (quad cab). Tighten the screw to 40 Nm (29 ft. lbs.). 5. Reinstall the trim onto the quarter inner panel (club cab). 6. Position the shoulder belt turning loop onto the quarter inner panel (club cab) or the C-pillar (quad cab). 7. Install and tighten the screw that secures the shoulder belt turning loop to the quarter inner panel (club cab) or the C-pillar (quad cab). Tighten the screw to 30 Nm (22 ft. lbs.). 8. Snap the trim cover over the rear shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the quarter inner panel (club cab) or the C-pillar (quad cab) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 5927 Seat Belt Tensioner: Diagrams Driver Seat Belt Tensioner (4 Door) Passenger Seat Belt Tensioner (4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 5928 Seat Belt Tensioner: Description and Operation Seat belt tensioners supplement the airbag system for all quad cab versions of this model. The seat belt tensioners are integral to the front seat belt retractors, which are secured within each B-pillar in the vehicle where they are concealed behind the B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar, a small pyrotechnically activated gas generator, and a short pigtail wire. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Airbag Control Module (ACM) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire front seat belt, retractor, and tensioner unit must be replaced. The seat belt tensioners are not intended for reuse, and both tensioners must be replaced following any airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. For seat belt tensioner service procedures, (Refer to RESTRAINTS/FRONT SEAT BELT & RETRACTOR - REMOVAL). The seat belt tensioners are deployed in conjunction with the airbags by a signal generated by the Airbag Control Module (ACM) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ACM sends the proper electrical signal to the tensioner, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce the likelihood of a harmful contact with interior components. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. All damaged, faulty or non-deployed seat belt tensioners must be disposed of properly (Refer to RESTRAINTS STANDARD PROCEDURE). The ACM monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5933 Passenger Airbag ON/OFF Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information Air Bag Deactivation Switch: Customer Safety Information WARNING - ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. - IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Customer Safety Information > Page 5936 Air Bag Deactivation Switch: Technician Safety Information WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 5937 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG ON/OFF SWITCH The passenger airbag ON/OFF switch is standard equipment on all versions of this model except quad cab. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel cluster bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate and nomenclature, the key cylinder actuator, and a small round lens with the text "OFF" imprinted on it. The "ON" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel cluster 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 face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel cluster 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 of the instrument panel wire harness. The harness take out is equipped with a molded plastic connector insulator that 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 faulty or damaged, the switch must be replaced. 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. The ignition key is the only key or object that should ever be inserted into 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 side airbag ON/OFF switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, and 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 indicator), 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. NOTE: Do not turn the ON/OFF switch with the ignition on. 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 Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected and provide circuit diagnostics. The ON/OFF switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the ON/OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code, the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. When the passenger airbag ON/OFF switch is in the OFF position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the OFF indicator of the switch. The ACM will also illuminate the OFF indicator of the switch for about 7 seconds each time the ignition switch is turned to the ON position as a bulb test. The ACM will also store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag ON/OFF switch or indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag ON/OFF switch or the ACM, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service Precautions > Page 5938 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the cluster bezel from the instrument panel. Fig.23 Passenger Airbag On/Off Switch 3. Remove the three screws that secure the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 4. Remove the passenger airbag ON/OFF switch and face plate from the cluster bezel as a unit. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the passenger airbag ON/OFF switch and face plate unit to the back of the cluster bezel. 2. Install and tighten the three screws that secure the passenger airbag ON/OFF switch face plate to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the cluster bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS STANDARD PROCEDURE VERIFICATION TEST) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5942 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5943 Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole single throw, plunger actuated, momentary switch Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 5944 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions Antenna Cable: Service Precautions 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 5951 Antenna Cable: Description and Operation ANTENNA BODY & CABLE All models use a fixed-length stainless steel rod- type antenna mast, installed on the right front fender of the vehicle. The antenna mast has a spiral groove cut down its length to reduce wind noise. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio receiver chassis. The antenna coaxial cable has an additional disconnect, located near the outboard side of the glove box opening on the back side of the lower instrument panel reinforcement. This additional disconnect allows the instrument panel assembly to be removed and installed without removing the radio receiver. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 5952 Antenna Cable: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The following four tests are used to diagnose the antenna with an ohmmeter: - Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to coaxial shield test. Antenna Tests The ohmmeter test lead connections for each test are shown in Antenna Tests. NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem; from the coaxial cable connection under the right end of the instrument panel near the outboard side of the glove box opening to the antenna base, and then from the coaxial cable connection to the radio chassis connection. Test 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1. Disconnect the antenna coaxial cable connector from the radio receiver chassis and isolate. Remove the antenna mast from the antenna base. 2. Insert one ohmmeter test lead into the socket for the antenna mast in the center of the antenna base. Connect the other test lead to the perimeter of the antenna base. Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or damaged antenna base and cable assembly. Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Disconnect the antenna coaxial cable connector from the radio receiver chassis. 2. Connect one ohmmeter test lead to the antenna mast in the center of the antenna base. Connect the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace the faulty base and cable, if required. Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the battery. Disconnect both battery cables, the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery negative terminal post. 2. The resistance should be less than one ohm. 3. If the resistance is more than one ohm, check the braided ground strap(s) connected to the engine and the vehicle body for being loose, corroded, or damaged. Repair the ground strap connections, if required. Test 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 5953 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then one ohm. 3. If the resistance is more then one ohm, clean and/or tighten the antenna base to fender mounting hardware. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Body and Cable Replacement Antenna Cable: Service and Repair Antenna Body and Cable Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. 3. Reach under the instrument panel outboard of the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 4. Disengage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. Antenna Mast Remove/Install - Typical 5. Unscrew the antenna mast from the antenna body. Antenna Cap Nut Remove/Install - Typical 6. Remove the antenna cap nut using an antenna nut wrench (Special Tool C-4816). 7. Remove the antenna adapter from the top of the fender. 8. Lower the antenna body through the mounting hole in the top of the fender. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Body and Cable Replacement > Page 5956 Antenna Mounting 9. Pull the antenna body and cable out through the opening between the right cowl side outer panel and the fender through the front door opening. 10. Disengage the antenna coaxial cable grommet from the hole in the right cowl side outer panel. 11. Pull the antenna coaxial cable out of the passenger compartment through the hole in the right cowl side outer panel. 12. Remove the antenna body and cable from the vehicle. INSTALLATION 1. Position the antenna body and cable in the opening between the right cowl side outer panel and the fender through the front door opening. 2. Push the antenna coaxial cable into the passenger compartment through the hole in the right cowl side outer panel. 3. Engage the antenna coaxial cable grommet in the hole in the right cowl side outer panel. 4. Position the antenna body through the mounting hole in the top of the fender. 5. Install the adapter over the antenna body from the top of the fender. 6. Install and tighten the antenna cap nut using an antenna nut wrench (Special Tool C-4816). Tighten the antenna cap nut to 8 Nm (70 in. lbs.). 7. Install and tighten the antenna mast onto the antenna body. Tighten the mast to 3.3 Nm (30 in. lbs.). 8. Engage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. 9. Engage the antenna coaxial cable in the retainer clips on the lower instrument panel support and the glove box. 10. Reach under the instrument panel outboard of the glove box to reconnect the antenna coaxial cable connector. 11. Install the trim cover onto the right cowl side inner panel. 12. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Body and Cable Replacement > Page 5957 Antenna Cable: Service and Repair Instrument Panel Antenna Cable Replacement 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. Reach under the instrument panel outboard of the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 3. Securely tie a suitable length of cord or twine to the instrument panel half of the antenna coaxial cable connector. This cord will be used to pull or "fish" the cable back into position during installation. 4. Disengage the instrument panel antenna cable from the retainer clips on the glove box opening and instrument panel support. 5. Remove the radio receiver from the instrument panel. 6. Pull the antenna cable out through the radio receiver opening in the instrument panel. 7. Untie the cord or twine from the instrument panel antenna cable connector, leaving the cord or twine in place of the cable in the instrument panel. 8. Remove the antenna cable from the instrument panel. INSTALLATION 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. Tie the end of the cord or twine that was used during instrument panel antenna cable removal securely to the connector on the end of the antenna coaxial cable being installed into the instrument panel. This cord will be used to pull or "fish" the cable back into position. 2. Using the cord or twine, pull the antenna cable through the radio receiver opening from under the instrument panel. 3. Install the radio receiver onto the instrument panel. 4. Engage the instrument panel antenna cable to the retainer clip on the lower instrument panel support and on the glove box opening. 5. Untie the cord or twine from the instrument panel half of the antenna coaxial cable connector. 6. Reach under the instrument panel outboard of the glove box to access and reconnect the antenna coaxial cable connector. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located in the steering column, near the ignition lock cylinder housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5962 Sentry Key Immobilizer Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5963 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located in the steering column, near the ignition lock cylinder housing. The SKIM has an integral molded plastic halo- like antenna ring that extends from one side. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Central Timer Module (CTM), and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKIM also sends security indicator status messages to the CTM over the PCI data bus to tell the CTM how to operate the security indicator. The CTM then controls the security indicator in the ElectroMechanical Instrument Cluster (EMIC) through a hard wired security indicator driver circuit. The security indicator status message from the SKIM tells the CTM to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends security indicator status messages to the CTM 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5964 test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKIM 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 SKIM will also send messages to the CTM to flash the security indicator whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5965 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector from the SKIM. 10. Remove the screw that secures the SKIM to the steering column. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper and lower shroud, and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Install the tilt lever knob. 10. Reinstall the steering column opening cover. 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Sentry Key Immobilizer Transponder TRANSPONDER KEY Each ignition key used in the Sentry Key Immobilizer System (SKIS) has an integral transponder chip. Ignition keys with this feature can be readily identified by a gray rubber cap molded onto the head of the key while conventional ignition keys have a black molded rubber cap. The transponder chip is concealed beneath the molded rubber cap, where it is molded into the head of the metal key Each new Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. The Sentry Key transponder if faulty or damaged, must be replaced. When the ignition switch is turned to the ON position, the Sentry Key Immobilizer Module (SKIM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKIM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKIM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKIM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKIM to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKIM over the PCI data bus, the engine will be disabled after about two seconds of operation. The ElectroMechanical Instrument Cluster (EMIC) will also respond to the invalid key message on the PCI data bus by flashing the security indicator ON and OFF. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKIM. Once the Sentry Key learns the Secret Key code of the SKIM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 5969 Alarm System Transponder: Service and Repair STANDARD PROCEDURE - TRANSPONDER PROGRAMMING All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory. The Sentry Key Immobilizer Module (SKIM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition switch lock cylinder in the vehicle for which it will be used. Once the additional or new key has been cut, the SKIM must be programmed to recognize it as a valid key. There are two possible methods to program the SKIM to recognize a new or additional valid key the Secured Access Method and the Customer Learn Method. Following are the details of these two programming methods. Secured Access Method The Secured Access method applies to all vehicles. This method requires the use of a DRB III scan tool. This method will also require that you have access to the unique four-digit PIN code that was assigned to the original SKIM. The PIN code must be used to enter the Secured Access Mode in the SKIM. This PIN number may be obtained from the vehicle owner, from the original vehicle invoice, or from the DaimlerChrysler Customer Center. Refer to the appropriate diagnostic information for the proper Secured Access method programming procedures. Customer Learn Method The Customer Learn feature is only available on domestic vehicles, or those vehicles which have a U.S. country code designator. This programming method also requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, or if the vehicle does not have a U.S. country code designator, the Secured Access Method must be used to program new or additional valid keys to the SKIM. The Customer Learn programming method procedures are as follows: 1. Obtain the blank Sentry Key(s) that are to be programmed as valid keys for the vehicle. Cut the blank key(s) to match the ignition switch lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. After the ignition switch has been in the ON position for longer than 3 seconds, but no more than 15 seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition switch lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted in the lock cylinder within 15 seconds of removing the first valid key. 4. About 10 seconds after the completion of Step 3, the security indicator in the instrument cluster will start to flash to indicate that the system has entered the Customer Learn programming mode. 5. Within 60 seconds of entering the Customer Learn programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About 10 seconds after the completion of Step 5, the security indicator will stop flashing, stay on solid for 3 seconds, then turn OFF to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the Customer Learn programming mode and the vehicle may now be started using the newly programmed valid Sentry Key Each of these steps must be repeated and completed in their entirety for each additional Sentry Key that is to be programmed. If the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the Customer Learn programming mode and the programming will be unsuccessful. The SKIS will also automatically exit the Customer Learn programming mode if it sees a non-blank Sentry Key transponder when it should see a blank, if it has already programmed eight (8)valid Sentry Keys, or if the ignition switch is turned to the OFF position for more than about 50 seconds. NOTE: If an attempt is made to start the vehicle while in the Customer Learn mode (security indicator flashing), the SKIS will respond as though the vehicle were being started with an invalid key. In other words, the engine will stall after about 2 seconds of operation. No faults will be set. - Once a Sentry Key has been programmed as a valid key to a vehicle, it cannot be programmed as a valid key for use on any other vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair STANDARD PROCEDURE - REMOTE KEYLESS ENTRY TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5978 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch (Premium) Passenger Cylinder Lock Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5979 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside the driver front door. The door cylinder lock switch is a resistor multiplexed switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the driver front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5980 Lock Cylinder Switch: Testing and Inspection 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5981 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Security Lamp/Indicator: Locations The security indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5985 Security Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Security ................................................................................................................................................ .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5986 Security Lamp/Indicator: Description and Operation A security indicator is standard equipment on all instrument clusters However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is mechanically disabled. The security indicator is located in the Information Center area of the instrument cluster, to the left of center. The security indicator consists of a stencil-like cutout of the word "SECURITY" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "SECURITY" text to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On models equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a hard wired input to the instrument cluster from the Central Timer Module (CTM) on the VTSS indicator driver circuit and, if the vehicle is so equipped, by a transistor on the instrument cluster circuit board based upon electronic messages received by the cluster from the Sentry Key Immobilizer Module (SKIM) over the Programmable Communications Interface (PCI) data bus. The security indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board at all times through the fused B(+) circuit; therefore, the LED will remain functional regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the CTM or by the instrument cluster transistor. The security indicator will be illuminated for the following reasons: - Bulb Test - If the vehicle is equipped with SKIS, each time the ignition switch is turned to the ON position the security indicator is illuminated by the instrument cluster for about three seconds based upon an electronic lamp-on message received from the SKIM as a bulb test. There is no bulb test performed for models that are not equipped with the optional SKIS. - VTSS Indication - During the sixteen second VTSS arming function, the CTM will flash the security indicator ON and OFF repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the CTM flashes the security indicator ON and OFF continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. If the VTSS has alarmed and rearmed, the CTM will flash the security indicator at a steady, slow rate for about thirty seconds after the VTSS is disarmed. - SKIM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the SKIM, the security indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKIM message. The indicator remains illuminated solid or continues to flash until the cluster receives a lamp-OFF message from the SKIM, or until the ignition switch is turned to the OFF position, whichever occurs first. For more information on the SKIS and the security indicator control parameters, (Refer to VEHICLE THEFT SECURITY/SENTRY KEY IMMOBILIZER SYSTEM - OPERATION). - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CTM provides a hard wired ground input to the instrument cluster circuitry through the VTSS indicator driver circuit whenever the ignition switch is in the OFF position and the VTSS is arming, armed, or triggered. When the ignition switch is turned to the ON or Start positions, the SKIM performs a self- test to decide whether the system is in good operating condition. The SKIM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. For further diagnosis of the security indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster flashes the SKIS indicator upon ignition ON, or turns ON the SKIS indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is inoperative. The VTSS indicator driver circuit input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the VTSS, the CTM, the SKIS, the PCI data bus, or the electronic message inputs to the instrument cluster that control the security indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation COMPASS / MINI-TRIP COMPUTER The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed time (ET) - shows the accumulated ignition-ON time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the HVAC control head. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If the RESET push button is depressed for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. Temperature The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the ON position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 5990 The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display mm and max temperatures of -40 °C (-40 °F) and 54 °C (130 °F). Fig. 10 Ambient Temperature Sensor AMBIENT TEMP SENSOR The ambient air temperature sensor is hardwired to the HVAC control and the HVAC control sends out a J1850 message to the overhead console. The ambient temperature sensor is a variable resistor (Fig. 5)mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the HVAC control head unit. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the HVAC control head unit. Based upon the resistance in the sensor, the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. UNIVERSAL TRANSMITTER On some models a Universal Transmitter transceiver is standard factory-installed equipment The universal transmitter transceiver is integral to the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons at the rear of the CMTC. The three universal transmitter push buttons can be easily identified by sight. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The universal transmitter operates on a non- switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the universal transmitter, see the owner's manual in the vehicle glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER On some models a Universal Transmitter transceiver is standard factory-installed equipment The universal transmitter transceiver is integral to the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons at the rear of the CMTC. The three universal transmitter push buttons can be easily identified by sight. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The universal transmitter operates on a non- switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the universal transmitter, see the owner's manual in the vehicle glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes Garage Door Opener Transmitter: Service and Repair Erasing Transmitter Codes STANDARD PROCEDURE - ERASING UNIVERSAL TRANSMITTER CODES To erase the universal transmitter codes, simply hold down the two outside buttons (1 and 3). NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes > Page 5996 Garage Door Opener Transmitter: Service and Repair Setting Transmitter Codes STANDARD PROCEDURE - SETTING UNIVERSAL TRANSMITTER CODES 1. Turn OFF the engine. 2. Erase the factory test codes by pressing the two outside buttons. 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly 4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes > Page 5997 Garage Door Opener Transmitter: Service and Repair Universal Transmitter Replacement REMOVAL 1. For universal transmitter removal and installation procedure, (Refer to COMPASS/MINI-TRIP COMPUTER - REMOVAL and INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Amplifier: Locations This power amplifier is a four channel unit. The power amplifier unit is mounted to the right cowl side inner panel under the passenger side end of the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 6002 Amplifier: Diagrams Amplifier C1 (Premium Sound) Amplifier C2 (Premium Sound) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 6003 Amplifier: Service Precautions 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 6004 Amplifier: Description and Operation AMPLIFIER (PREMIUM SYSTEM) Models equipped with the Infinity premium speaker package have a separate power amplifier unit. This power amplifier is a four channel unit. The power amplifier unit is mounted to the right cowl side inner panel under the passenger side end of the instrument panel. The power amplifier unit can be accessed for service by removing the trim from the right cowl side inner panel. The power amplifier receives fused battery current from a fuse in the Junction Block (JB) at all times. The internal circuitry of the power amplifier switches the amplifier on based upon a fused 12 volt output signal that is received from the radio receiver whenever the radio is turned ON. The power amplifier receives the sound signal inputs for four speaker channels from the radio receiver, then sends the amplified speaker outputs for each of those channels to the six speakers. The Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior, for superior sound quality. This design allows one part number to be used for several vehicles. The amplifier reads the VIN from the Programmable Communications Interface (PCI) data bus. The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 6005 Amplifier: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. The amplifier, wiring and speakers should be checked if there is no sound output from the speakers. (Refer to SPEAKER - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 6006 Amplifier: Service and Repair 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. 3. Disconnect the two instrument panel wire harness connectors from the connector receptacles on the bottom of the power amplifier. 4. Remove the three screws that secure the power amplifier to the right cowl side inner panel. 5. Remove the power amplifier from the right cowl side inner panel. INSTALLATION 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the power amplifier to the right cowl side inner panel. 2. Install the three screws that secure the amplifier to the right cowl side inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors to the connector receptacles on the bottom of the power amplifier. 4. Install the trim cover onto the right cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed Compact Disc Player (CD): Customer Interest Audio System - 'CD ERR' Message Displayed NUMBER: 08-028-03 GROUP: Electrical DATE: September 19, 2003 SUBJECT: Radio CD ERR Message MODELS: 2002 - 2003 (AN) Dakota 2002 - 2003 (DN) Durango 2002 - 2004 (DR) Ram Truck 2004 (HB) Durango 2002 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2002 - 2004 (PL) Neon 2002 - 2004 (PT) Chrysler PT Crusier 2002 - 2004 (RG) Chrysler Voyager (International Markets) 2002 - 2004 (RS) Town & Country/Voyager/Caravan 2002 - 2004 (TJ) Wrangler 2002 - 2004 (WG) Grand Cherokee (International Markets) 2002 - 2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper NOTE: This bulletin applies to vehicles equipped radio sales codes RAZ, RAD, RBK, RBP, RAH, REF, RAQ and RAR. DISCUSSION: Here are some common problems of why a CD ERR may occur: 1. CD's are not always compatible with a CD player. Usually these are homemade CD's (write/re-write), however some low quality CD's may not be compatible. 2. Scratches on a CD. Most of the time a CD will skip when the player sees a scratch but in some cases the scratches are so severe that a CD ERR will occur. 3. Finger prints on the CD. The oil from finger prints may prevent the Optical Pickup from reading the disc. 4. Foreign materials on a CD such as; carpet fibers, liquid spills, candy, etc. may prevent the Optical Pickup from reading a disc. 5. CD's warped from being in extreme heat. If a CD is warped too much then it should not fit into the CD slot, thus preventing insertion. However, some CD's that are not perfectly flat may be inserted with little effort. The CD player may or may not read these CD's. 6. In climate condition where the CD player is exposed to frigid temperatures or high humidity condensation may form on the Optical Pickup. This condition will correct itself once the vehicle's cabin temperature stabilizes. What a dealer should do before removing a CD player for repair. 1. Find out as much information as possible about the failure from the customer. a. Does the CD player work at all or is it intermittent? b. Does the failure occur when using certain CD's? c. Are the CD's homemade or inexpensive CD's? d. Does the failure occur during the first few minutes when the temperature is either frigid or hot and humid? e. Will the customer make his CD's available to you for testing and inspection? Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 6015 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed Compact Disc Player (CD): All Technical Service Bulletins Audio System - 'CD ERR' Message Displayed NUMBER: 08-028-03 GROUP: Electrical DATE: September 19, 2003 SUBJECT: Radio CD ERR Message MODELS: 2002 - 2003 (AN) Dakota 2002 - 2003 (DN) Durango 2002 - 2004 (DR) Ram Truck 2004 (HB) Durango 2002 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2002 - 2004 (PL) Neon 2002 - 2004 (PT) Chrysler PT Crusier 2002 - 2004 (RG) Chrysler Voyager (International Markets) 2002 - 2004 (RS) Town & Country/Voyager/Caravan 2002 - 2004 (TJ) Wrangler 2002 - 2004 (WG) Grand Cherokee (International Markets) 2002 - 2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper NOTE: This bulletin applies to vehicles equipped radio sales codes RAZ, RAD, RBK, RBP, RAH, REF, RAQ and RAR. DISCUSSION: Here are some common problems of why a CD ERR may occur: 1. CD's are not always compatible with a CD player. Usually these are homemade CD's (write/re-write), however some low quality CD's may not be compatible. 2. Scratches on a CD. Most of the time a CD will skip when the player sees a scratch but in some cases the scratches are so severe that a CD ERR will occur. 3. Finger prints on the CD. The oil from finger prints may prevent the Optical Pickup from reading the disc. 4. Foreign materials on a CD such as; carpet fibers, liquid spills, candy, etc. may prevent the Optical Pickup from reading a disc. 5. CD's warped from being in extreme heat. If a CD is warped too much then it should not fit into the CD slot, thus preventing insertion. However, some CD's that are not perfectly flat may be inserted with little effort. The CD player may or may not read these CD's. 6. In climate condition where the CD player is exposed to frigid temperatures or high humidity condensation may form on the Optical Pickup. This condition will correct itself once the vehicle's cabin temperature stabilizes. What a dealer should do before removing a CD player for repair. 1. Find out as much information as possible about the failure from the customer. a. Does the CD player work at all or is it intermittent? b. Does the failure occur when using certain CD's? c. Are the CD's homemade or inexpensive CD's? d. Does the failure occur during the first few minutes when the temperature is either frigid or hot and humid? e. Will the customer make his CD's available to you for testing and inspection? Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 6021 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions Radio/Stereo Noise Filter: Service Precautions WARNING: 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6026 Radio/Stereo Noise Filter: Description and Operation RADIO NOISE SUPPRESSION GROUND STRAP Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this vehicle to control RFI or EMI noise include the following: Radio antenna base ground - Radio receiver chassis ground wire or strap - Engine-to-body ground strap(s) - Exhaust system-to-body ground strap (4.7 L engines only) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. For more information on the spark plugs and secondary ignition components, refer to ELECTRICAL/IGNITION CONTROLS. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6027 Radio/Stereo Noise Filter: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Inspect the ground paths and connections at the following locations: - Blower motor - Electric fuel pump - Engine-to-body ground strap(s) - Generator - Ignition module - Radio antenna base ground - Radio receiver chassis ground wire or strap - Wiper motor. If the source of RFI or EMI noise is identified as a component on the vehicle (i.e., generator, blower motor, etc.), the ground path for that component should be checked. If excessive resistance is found in any ground circuit, clean, tighten, or repair the ground circuits or connections to ground as required before considering any component replacement. For service and inspection of secondary ignition components, refer to ELECTRICAL/IGNITION CONTROLS. Inspect the following secondary ignition system components: - Distributor cap and rotor - Ignition coil - Spark plugs - Spark plug wire routing and condition. Reroute the spark plug wires or replace the faulty components as required. If the source of the RFI or EMI noise is identified as two-way mobile radio or telephone equipment, check the equipment installation for the following: - Power connections should be made directly to the battery and fused as closely to the battery as possible. - The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead console compass, if the vehicle is so equipped. - The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and should be routed away from the factory-installed vehicle wire harnesses whenever possible. - The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR). Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio communications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio frequency ranges. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6028 Radio/Stereo Noise Filter: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Exhaust System-to-body Ground Strap 1. Raise and support the vehicle. Fig.7 Exhaust System-To-Body Ground Strap Remove/Install - Typical 2. Remove the nut and washer that secures the exhaust system-to-body ground strap eyelet terminal to the exhaust pipe clamp. 3. Remove the screw that secures the exhaust system-to-body ground strap eyelet terminal to the right body sill panel. 4. Disengage the clip that secures the exhaust system-to-body ground strap from the hole on the top of the right frame rail. 5. Remove the exhaust system-to-body ground strap from over the top of the right frame rail. Engine-To-body Ground Straps Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6029 Fig.8 Engine-To-Body Ground Strap Remove/Install - Typical 1. Remove the nut and washer that secures the left engine-to-body ground strap eyelet terminal to the weld stud on the left side of the lower plenum panel. 2. On 6 and 8 cylinder engines only, remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard weld stud on the right side of the lower plenum panel. Fig.9 Engine-To-Body Ground Strap Remove/Install 3. On 4 cylinder engines only, remove the nut and washer that secures the left engine-to-body ground strap eyelet terminal to the stud on the left rear corner of the engine cylinder head. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6030 Fig.10 Engine-To-Body Ground Strap Remove/Install Fig.11 Engine-To-Body Ground Strap Remove/Install 4. On 6 and 8 cylinder engines only, remove the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head or. 5. On 6 and 8 cylinder engines only, remove the screw that secures the right engine-to-body ground strap eyelet terminal to the rear of the right cylinder head or. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6031 Fig.12 Engine-To-Body Ground Strap Remove/Install - 4.7L Engine Only 6. On 4.7L engines only, remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal and the wire harness grounds to the weld stud on the right front fender wheelhouse inner panel. Fig.13 Left Engine-To-Body Ground Strap Remove/Install - 4 Cylinder Engine Only 7. On 4.7L engines only remove the screw and washer that secures the right engine-to-body ground strap eyelet terminal to the transmission at the right rear corner of the engine block. 8. On 3.9L and 5.9L engines only, remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard rear valve cover stud of the right cylinder head. 9 Remove the engine-to-body ground strap(s) from the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6032 INSTALLATION Exhaust System-to-body Ground Strap 1. Position the exhaust system-to-body ground strap over the top of the right frame rail. 2. Engage the clip that secures the exhaust system-to-body ground strap in the hole on the top of the right frame rail. 3. Install and tighten the screw that secures the exhaust system-to-body ground strap eyelet terminal to the right body sill panel. Tighten the screw to 5.0 Nm (45 in. lbs.). 4. Position the exhaust system-to-body ground strap eyelet terminal over the exhaust pipe clamp U-bolt. 5. Install and tighten the nut and washer that secures the exhaust system-to-body ground strap eyelet terminal to the exhaust pipe clamp. Tighten the nut to 27.1 Nm (20 ft. lbs.). 6. Lower the vehicle. Engine To Body Ground Straps 1. Position the engine-to-body ground strap(s) in the engine compartment. 2. On 3.9L and 5.9L engines only position the right engine-to-body ground strap eyelet terminal over the inboard rear valve cover stud of the right cylinder head. 3. On 3.9L and 5.9L engines only, install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard rear valve cover stud of the right cylinder head. Tighten the nut to 2.8 Nm (25 in. lbs.). 4. On 4.7L engines only install and tighten the screw and washer that secures the right engine-tobody ground strap eyelet terminal to the transmission at the right rear corner of the engine block. Tighten the screw to 67.8 Nm (50 ft. lbs.). 5. On 4.7L engines only, position the right engine- to-body ground strap eyelet terminal and the wire harness grounds over the weld stud on the right front fender wheelhouse inner panel. 6. On 4.7L engines only install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet terminal and the wire harness grounds to the weld stud on the right front fender wheelhouse inner panel. Tighten the nut to 11.8 Nm (105 in. lbs.). 7. On 6 and 8 cylinder engines only install and tighten the screw that secures the right engine-to body ground strap eyelet terminal to the rear of the right cylinder head. On 3.9L and 5.9L engines, tighten the screw to 10.2 Nm (90 in. lbs.). On 4.7L engines, tighten the screw to 10.7 Nm (95 in. lbs.). 8. On 6 and 8 cylinder engines only, install and tighten the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head. On 3.9L and 5.9L engines, tighten the screw to 10.2 Nm (90 in. lbs.). On 4.7L engines, tighten the screw to 10.7 Nm (95 in. lbs.). 9. On 4 cylinder engines only, position the left engine-to-body ground strap eyelet terminal over the stud on the left rear corner of the engine cylinder head. 10. On 4 cylinder engines only, install and tighten the nut and washer that secures the left engine-to- body ground strap eyelet terminal to the stud on the left rear corner of the engine cylinder head. Tighten the nut to 2.8 Nm (25 in. lbs.). 11. On 6 and 8 cylinder engines only, position the right engine-to-body ground strap eyelet over the inboard weld stud on the right side of the lower plenum panel. 12. On 6 and 8 cylinder engines only install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet to the inboard weld stud on the right side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). 13. Install and tighten the nut and washer that secures the left engine-to-body ground strap eyelet to the weld stud on the left side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6036 Remote Switch: Service Precautions 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6037 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULDESCRIPTION) for more information on this component. Fig.14 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION) for more information on this component. The remote radio switches are resistor multiplexed units that are hard wired to the high-line Central Timer Module (CTM) through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6038 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. 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. Fig.15 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control MUX circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6039 5. Check for continuity between the radio control MUX circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CTM and the Programmable Communications Interface (PCI) data bus. If not OK, repair the open radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6040 Remote Switch: Service and Repair 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 side airbag module from the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL) for the procedures. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Refer to ELECTRICAL/SPEED CONTROL for the procedures. Fig.16 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 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. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6041 4. Install the speed control switch onto the steering wheel. Refer to ELECTRICAL/SPEED CONTROL for the procedures. 5. Install the driver side airbag module onto the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - INSTALLATION) for the procedures. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Left Front Door Speaker (Base) Left Front Door Tweeter (Midline/Premium) Left Front Door Woofer (Midline/Premium) Left Rear Speaker Right Front Door Speaker (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6045 Right Front Door Tweeter (Midline/Premium) Right Front Door Woofer (Midline/Premium) Right Rear Speaker Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6046 Speaker: Service Precautions 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6047 Speaker: Description and Operation STANDARD The standard equipment speaker system includes speakers in four locations. One full-range 16.5 centimeter (6.50 inch) diameter speaker is located in each front door. There is also one full-range speaker located in each rear cab side panel, 13.3 centimeter (5.25 inch) diameter units for the standard cab models, and 16.5 centimeter (6.50 inch) diameter units for the club cab models. On quad cab models, the 16.5 centimeter (6.50 inch) diameter full-range speaker units are located in each rear door, instead of in the cab side panel. Each of the four full-range speakers used in the standard speaker system is driven by the amplifier that is integral to the factory-installed radio receiver. PREMIUM The optional premium speaker system features Infinity model speakers in six locations. Each of the standard speakers in the four speaker stereo system are replaced with Infinity model speakers, and an additional 6.9 centimeter (2.75 inch) diameter Infinity dome tweeter is mounted high in the front door trim panels. The premium speaker system also includes an additional Infinity power amplifier. The total available power of the premium speaker system is about 160 watts. The six Infinity speakers used in the premium speaker system are all driven by the radio receiver through an Infinity power amplifier. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6048 Speaker: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. 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. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. If all speakers are inoperative, check the radio fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier. disconnect wire harness connector at output side of amplifier. Go to Step 4. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6049 Speaker: Service and Repair REMOVAL Front Door Lower Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Fig.17 Front Door Lower Speaker 3. Remove the screws that secure the speaker to the front door. 4. Pull the speaker away from the mounting hole in the front door inner panel far enough to access the wire harness connector. 5. Disconnect the front door wire harness connector from the speaker. 6. Remove the speaker from the front door inner panel. Front Door Upper Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. 3. Remove the screws that secure the front door upper speaker to the back of the trim panel. Fig.18 Front Door Upper Speaker Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6050 4. Remove the front door upper speaker from the trim panel. Rear Door Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the rear door. Fig.19 Rear Door Speaker - Quad Cab 3. Remove the screws that secure the speaker to the rear door. 4. Pull the speaker away from the mounting hole in the rear door far enough to access the wire harness connector. 5. Disconnect the rear door wire harness connector from the speaker. 6. Remove the speaker from the rear door. Rear Cab Side Speaker - CLUB CAB 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the rear cab side inner panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6051 Fig.20 Rear Cab Side Panel Speaker - Club Cab 3. Remove the three screws that secure the speaker to the rear cab side inner panel. 4. Pull the speaker away from the mounting hole in the rear cab side inner panel far enough to access the wire harness connector. 5. Disconnect the body wire harness connector from the speaker connector receptacle. 6. Remove the speaker from the rear cab side inner panel. Rear Cab Side Speaker - REGULAR CAB 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the B-pillar. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6052 Fig.21 Rear Cab Side Panel Speaker - Regular Cab 3. Pull the B-pillar trim away from the cab side panel far enough to access the speaker wire harness connector. 4. Disconnect the body wire harness connector from the speaker connector receptacle. 5. Remove the two screws that secure the speaker to the back of the B-pillar trim. 6. Remove the speaker from the back of the B-pillar trim. INSTALLATION Front Door Lower Speaker 1. Position the speaker to the front door. 2. Connect the front door wire harness connector to the speaker. 3. Position the speaker into the mounting hole in the front door. 4. Install the mounting screws. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the trim panel onto the front door. 6. Connect the battery negative cable. Front Door Upper Speaker 1. Position the front door upper speaker to the back of the trim panel. 2. Install mounting screws. Tighten the screws to 1.3 Nm (12 in. lbs.). 3. Connect the door wire harness connector to the front door upper speaker. 4. Install the trim panel onto the front door. 5. Connect the battery negative cable. Rear Door Speaker 1. Connect the rear door wire harness connector to the speaker. 2. Position the speaker into the mounting hole in the rear door inner panel. 3. Install mounting screws. Tighten the screws to 3.9 Nm (35 in. lbs.). 4. Install the trim panel onto the rear door. 5. Connect the battery negative cable. Rear Cab Side Speaker - CLUB CAB 1. Position the speaker to the rear cab side inner panel. 2. Connect the body wire harness connector to the speaker. 3. Install mounting screws. Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the trim panel onto the rear cab side inner panel . 5. Reconnect the battery negative cable. Rear Cab Side Speaker - REGULAR CAB Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6053 1. Position the speaker onto the back of the B-pillar trim. 2. Install mounting screws. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the body wire harness connector to the speaker. 4. Install the trim panel onto the B-pillar. 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located in the steering column, near the ignition lock cylinder housing. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6058 Sentry Key Immobilizer Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6059 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located in the steering column, near the ignition lock cylinder housing. The SKIM has an integral molded plastic halo- like antenna ring that extends from one side. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Central Timer Module (CTM), and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKIM also sends security indicator status messages to the CTM over the PCI data bus to tell the CTM how to operate the security indicator. The CTM then controls the security indicator in the ElectroMechanical Instrument Cluster (EMIC) through a hard wired security indicator driver circuit. The security indicator status message from the SKIM tells the CTM to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends security indicator status messages to the CTM 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 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6060 test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKIM 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 SKIM will also send messages to the CTM to flash the security indicator whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6061 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector from the SKIM. 10. Remove the screw that secures the SKIM to the steering column. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper and lower shroud, and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Install the tilt lever knob. 10. Reinstall the steering column opening cover. 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6066 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch (Premium) Passenger Cylinder Lock Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6067 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside the driver front door. The door cylinder lock switch is a resistor multiplexed switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the driver front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6068 Lock Cylinder Switch: Testing and Inspection 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6069 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6073 Remote Switch: Service Precautions 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6074 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULDESCRIPTION) for more information on this component. Fig.14 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION) for more information on this component. The remote radio switches are resistor multiplexed units that are hard wired to the high-line Central Timer Module (CTM) through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6075 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. 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. Fig.15 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control MUX circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6076 5. Check for continuity between the radio control MUX circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CTM and the Programmable Communications Interface (PCI) data bus. If not OK, repair the open radio control MUX circuit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6077 Remote Switch: Service and Repair 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 side airbag module from the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL) for the procedures. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Refer to ELECTRICAL/SPEED CONTROL for the procedures. Fig.16 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 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. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 6078 4. Install the speed control switch onto the steering wheel. Refer to ELECTRICAL/SPEED CONTROL for the procedures. 5. Install the driver side airbag module onto the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG - INSTALLATION) for the procedures. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair Towing Information: Service and Repair STANDARD PROCEDURE Fig.8 Tow Vehicles With Approved Equipment TOWING RECOMMENDATIONS A vehicle equipped with an SAE approved Wheel- lift towing device can be used to tow all Short Bed DAKOTA vehicles. Long Bed vehicles must be towed with a Flat-bed device (Fig. 8). When towing a 4WD vehicle, use tow dollies under the opposite end of the vehicle. SAFETY PRECAUTIONS NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flat bed device to transport a loaded vehicle. GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. RAMP ANGLE If a vehicle with flat bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. TOWING WHEN KEYS ARE NOT AVAILABLE When the vehicle is locked and keys are not available, use a flat bed hauler. A Sling-type device can be used on 4WD vehicles provided all the wheels are lifted OFF the ground using tow dollies. TWO WHEEL DRIVE VEHICLE TOWING TOWING-REAR END LIFTED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Page 6083 Fig.9 Short Bed Vehicle Towing-Typical Fig.10 Long Bed Vehicle Towing-Typical CAUTION: Short bed vehicle must be towed with a Wheel-lift device (Fig. 9) or transported on a flat bed (Fig. 10) Long bed vehicle must be transported on a flat bed 2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph). 1. Attach wheel lift device to rear wheels. 2. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 3. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 4. Secure steering wheel in straight ahead position with a clamp device designed for towing. 5. Verify that steering components are in good condition. 6. Shift the transmission to NEUTRAL. TOWING-FRONT END LIFTED When lifting from the front end, all vehicles must be towed with a Wheel-lift device or transported on a flat bed. 1. Attach Wheel-lift device to front wheels. 2. Attach the safety chains to the disabled vehicle at the frame rails. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 3. Turn the ignition switch to the OFF position to unlock the steering wheel. TWO WHEEL DRIVE-MANUAL AND AUTOMATIC TRANSMISSION Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. FOUR WHEEL DRIVE VEHICLE TOWING FOUR WHEEL DRIVE TOWING-REAR END LIFTED CAUTION: Short bed vehicles must be towed with a Wheel-lift device (Fig. 9) or transported on a flat bed. Long bed vehicles must be transported on a flat bed (Fig. 10). When using a Wheel-lift device, all wheels must be lifted off the ground using tow dollies. 1. Raise the front of the vehicle off the ground and install tow dollies under front wheels. 2. Attach wheel lift device to rear wheels. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Page 6084 3. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 5. Secure steering wheel in straight ahead position with a clamp device designed for towing. 6. Shift the transfer case to NEUTRAL. FOUR WHEEL DRIVE TOWING-FRONT END LIFTED When lifting from the front end, all vehicles must be towed with a wheel-lift device or transported on a flat bed. 1. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. 2. Attach wheel lift device to front wheels. 3. Attach the safety chains to the disabled vehicle at the frame rails. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Shift the transfer case to NEUTRAL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Trailer Connector: Connector Views C341 (Trailer Tow) Trailer Tow Connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Trailer Connector: Electrical Diagrams 8w-54-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 8w-54-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Support trailer hitch on a suitable lifting device. 2. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped. Fig. 9 3. Remove bolts attaching trailer hitch to frame rails (Fig. 9). 4. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rails, remove lifting device and tighten to 108 N.m (80 ft.lbs.). 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Trailer Connector: Connector Views C341 (Trailer Tow) Trailer Tow Connector Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Trailer Connector: Electrical Diagrams 8w-54-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 8w-54-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Trip Computer: Locations The compass mini-trip computer is located in the overhead console on models equipped with this option. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 6137 Trip Computer: Description and Operation COMPASS / MINI-TRIP COMPUTER The compass/mini-trip computer is located in the overhead console on models equipped with this option. The compass/mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass/mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant Fuel Economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed Time (ET) - shows the accumulated ignition-ON time since the last trip computer reset. - Step Button - Press this button to cycle through all the mini-trip computer displays. - US/M Button - Press this button to convert all vehicle displays from US to Metric to US. - Blank Screen - the compass/mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the HVAC control head. Data input for all other compass/mini-trip computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. The compass/mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass/mini-trip computer module must be replaced. The compass/mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass/mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass/mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass/mini-trip computer features several functions that can be reset. If the RESET push button is depressed for more than 1 second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. For more information on the features and control functions of the compass/mini-trip computer, see the owner's manual in the vehicle glove box. COMPASS While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 6138 Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately 5 seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. TEMPERATURE The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the ON position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass/mini-trip computer will display mm and max temperatures of -40 °C (-40 °F) and 54 °C (130 °F). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 6139 Trip Computer: Testing and Inspection COMPASS/MINI-TRIP COMPUTER TEST If the problem with the Compass/Mini-Trip Computer module is an inaccurate or scrambled display refer to Self-Diagnostic Test below. If the problem with the Compass/Mini-Trip Computer module is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB scan tool and the proper Diagnostic Procedures manual to test for the correct dimming message inputs being received from the instrument cluster over the J1850 data bus. If the problem is a no-display condition, use the following procedures. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring. 1. Check the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavities of the roof wire harness connector for the overhead console and a good ground. There should be continuity If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the overhead console. If OK, refer to Self-Diagnostic Test below, for further diagnosis of the Compass/Mini-Trip Computer module and the J1850 data bus. If not OK, repair the open fused ignition switch output (run/start) circuit to the junction block as required. SELF-DIAGNOSTIC TEST A self-diagnostic test is used to determine that the Compass/Mini-Trip Computer module is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The Compass/Mini-Trip Computer self - test can also be performed using a DRB III. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the OFF position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/ON position. 2. Continue to hold both buttons depressed until the Compass/Mini-Trip Computer module enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the Compass/Mini-Trip Computer module performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - J1850 Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the Compass/Mini-Trip Computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but Compass/Mini-Trip Computer operation is still improper, the use of a DRB III scan tool and the proper Diagnostic Procedures manual are required for further diagnosis. - If the "FAIL" message is displayed, the Compass/Mini-Trip Computer module is faulty and must be replaced. - If the "PASS" message is displayed, the Compass/Mini-Trip Computer module is OK, no faults are present. - If any VFD segment should fail to light during the display segment test, the Compass/Mini-Trip Computer module is faulty and must be replaced. 4. If the first seven tests pass, the Compass/minitrip computer shall verify that all the required J1850 messages are present on the J1850 bus. If all required J1850 messages are present on the J1850 bus, or if the ignition switch is turned to the OFF position, the Compass/Mini-Trip Computer module will automatically return to normal operation. The required J1850 messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine OFF Duration message - Ambient Air Temperature message NOTE: The Fuel Used J1850 message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the Compass/Mini-Trip Computer to exit Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 6140 diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. Refer to Compass Variation Adjustment in the Service Procedures. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Refer to Compass Demagnetizing in the Service Procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 6141 Trip Computer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner (Refer to OVERHEAD CONSOLE - REMOVAL). 3. Remove the four screws that secure the compass mini-trip computer module to the overhead console housing. 4. Pull the compass mini-trip computer module away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the compass mini-trip computer module housing by pushing the connector firmly toward the left side of the overhead console housing. 6. Disconnect the overhead console wire harness connector from the compass mini-trip computer module connector receptacle. 7. Remove the compass mini-trip computer module from the overhead console housing. INSTALLATION 1. Position the compass mini-trip computer module onto the overhead console housing. 2. Reconnect the overhead console wire harness connector to the compass mini-trip computer module connector receptacle. 3. Engage the overhead console wire harness connector onto the mount on the compass mini-trip computer module housing by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 4. Install and tighten the four screws that secure the compass mini-trip computer module to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the overhead console onto the headliner. Refer to Overhead Console in the Removal and Installation for the procedures. 6. Reconnect the battery negative cable. NOTE: If a new compass mini-trip computer has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures for the procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations Central Timer Module ( CTM ) High Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 6147 Central Timer Module ( CTM ) High Option: Diagrams Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 6148 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Page 6149 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information DANGER!!! ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection and remove any metal jewelry, such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 6152 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "lock" position. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the Miller tool #8815 (not the wire end or terminal) in the connector. Do not probe a wire through the insulation; this will damage the wire and eventually cause the wire to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description Central Timer Module ( CTM ) High Option: Description and Operation System Description SYSTEM DESCRIPTION The body system on the Dakota (AN) and Dakota Quad Cab (AN84) consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6155 Central Timer Module ( CTM ) High Option: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp and chime contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp and chime are driven with messages relayed to the Electro/ Mechanical Instrument Cluster (EMIC and CTM) from the ACM via the PCI bus. The AIRBAG warning lamp and chime are the only point at which "symptoms" of a system malfunction can be observed by the customer. When- ever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF; there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Passenger Side Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. 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. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. SPECIAL TOOLS Some airbag diagnostic test use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver and Passenger Airbag, clockspring, or seat belt tensioner (use a jumper if needed). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6156 Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective components has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed squib wiring can be tested for open and shorted conditions. SEAT BELT TENSIONER Front seat belt systems incorporate Seat Belt Tensioner (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6157 remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio Digital Signal Processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 AN/AN84 Dakota amplifier has four channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. - PCI Amplifier Test - This test will detect a PCI bus or checksum failure. - Input Test - This test will detect the activity on the amplifiers input channels from the radio. - Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Central Timer Module CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) - Horn Chirp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6158 - Optical Chirp The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. Chime System CHIME SYSTEM The chime system is built into the CTM. There are two chime rates - Low: 50 chimes per minute for reminders, and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left ON. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light ON the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Ignition OFF, cargo lights ON, drivers door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning (if vehicle speed>0) - Transmission temperature lamp - Turn signal ON reminder warning - Button pushed on compass mini-trip computer (reset) - ABS light ON - Over speed warning GULF COAST COUNTRY (GCC only) - Water in fuel (diesel) Compass/Mini-Trip Computer (CMTC) COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (Miles Per Gallon) or 1/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or 1/100 Km. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions and a chime will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6159 the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly OFF of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Head-lamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. Enhanced Accident Response ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Exterior Lighting EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition Off while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF, The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON, the delay will be canceled and the headlamps will turn OFF immediately. During the delay period, only the headlamps are turned ON and the park lamps/fog lamps are turned OFF. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6160 The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned OFF and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. A 15 minute timeout is initiated if the ignition is OFF and the headlamp switch is cycled from OFF to ON (lamp mode). Heating & A/C System HEATING & A/C SYSTEM System Availability - A Single-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The A/C-Heater Control Module: Is fully addressable with the DRB III. - Communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - Uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - Provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - Controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - Controls heated mirror operation (if equipped). - Controls electronic door actuator operation. The Single-Zone HVAC system uses: One, two-wire electronic blend door actuator. - One, two-wire electronic mode door actuator. - One, two-wire electronic recirculation door actuator. > A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. System Revisions The 2002 AN and AN84 HVAC system remains mostly carryover from 2001. Revisions to the 2002 HVAC system include: New Diagnostic Trouble Codes for a short high on the defog relay control circuit. - A new System Test called the Actuator Circuit Test. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRB III. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRB III. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator (if equipped) from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRB III. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6161 - homes and repositions door actuators. - monitors for faults on the actuator circuits. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator (if equipped) to flash while the test is running. > If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator (if equipped) from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRB III. - monitors for faults on the actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRB III as test messages only after running the test. - faults will not display on the DRB III as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test: CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause B fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: > indicates that a specific determination of which lines are shorted could not be made. > is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: > XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. > XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. > the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - After the Actuator Circuit Test is run on systems with less than six actuators: > the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). > If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed and the ignition is in the RUN or ACCY position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6162 sends voltage to the cargo lamps. When an unlock button of the RKE is pressed, the cargo lights will turn ON for 30 seconds, similar to the illuminated entry feature. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps and cargo lights due to the following. Leaving a door open, dome lamp switch ON, reading/ vanity lamp switch on or glove box door open for more than 15 minutes while the ignition is OFF. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the LOCK position, all the doors will lock. For unlocking, if the key is turned to the UNLOCK position once, only that door will unlock. If the key is then turned a second time to the UNLOCK position within 4 seconds, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The Highline CTM provides for Remote Keyless Entry (RKE). The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Vehicle Communication Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6163 VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the AN and AN84: Airbag Control Module - Amplifier - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > System Description > Page 6164 - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Vehicle Theft Security/System VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. Windshield Wiper System WINDSHIELD WIPER SYSTEM The AN or AN84 truck utilize speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module ( CTM ) High Option: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - chime inoperative Chime Inoperative Exterior/Interior Lamps On & Driver Door Open Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Inoperative With Drivers Seat Belt Unfastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6167 Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire shorted to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6168 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central Timer Module Chime Sounds With Driver Seat Belt Fastened Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6169 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6170 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense shorted to ground - Central timer module - key-in ignition shorted Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in CTM - Central timer module Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6171 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6172 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6173 Down or Page Up function to display the information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6174 Central Timer Module ( CTM ) High Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6175 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8443 Airbag Load Tool 8310 Airbag Load Tool Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL 1. Remove the front bumper. 2. Remove the bolts attaching the fascia to the bumper. 3. Separate fascia from bumper. INSTALLATION 1. Position fascia on bumper. 2. Install the bolts attaching the fascia to the bumper. 3. Install the front bumper. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair Rear Bumper: Service and Repair REAR BUMPER REMOVAL 1. Support rear bumper on a suitable lifting device. Fig. 2 2. Remove bolts attaching inner bumper brackets to frame rails (Fig. 2). 3. Disengage license plate lamp wire connector from body wire harness, if equipped. 4. Separate rear bumper from vehicle. INSTALLATION 1. Place bumper on a suitable lifting device and raise into position. 2. Engage license plate lamp wire connector from body wire harness, if equipped. 3. Install bolts attaching inner bumper brackets to frame rails and tighten to 94 N.m (70 ft.lbs.). 4. Remove lifting device. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE Removal 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to door handle. 3. Roll glass up. 4. Remove fastener access plug from door end panel. 5. Disengage lock cylinder to latch rod from the latch. 6. Disengage outside handle to latch rod from the latch. 7. Remove nuts attaching outside door handle to door. 3. Separate outside handle from the door. Installation 1. Position outside handle in the door. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 6191 2. Install nuts attaching outside door handle to door and tighten to 5 Nm (45 in. lbs). 3. Engage outside handle to latch rod to the latch. 4. Engage lock cylinder to latch rod to the latch. 5. Install fastener access plug in the door end panel. 6. Reposition the water damn. 7. Install door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole and insert a 5/32 in hex-wrench through the hole and into the adjustment screw. 2. Loosen the screw and operate the outside handle several times to release any restriction because of mis-alignment. 3. Tighten the adjustment screw to 3 Nm (30 in. lbs.). 4. Test handle for proper operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6195 Front Door Latch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Peel back water dam as necessary. 3. For access to latch roll up glass and remove bolts affaching rearward glass run channel to door. Move and secure glass run channel. 4. Remove screws attaching latch to door shut face. 5. Disconnect wire harness connector for power door locks, if equipped. 6. Disconnect lock button to latch rod from the latch. 7. Disconnect lock cylinder to latch rod from the latch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6196 8. Disconnect inside handle to latch rod from the latch. 9. Disconnect outside handle to latch rod from the latch. 10. Separate latch from door. INSTALLATION 1. Connect latch rod to outside handle. 2. Connect inside handle to latch rod to the latch. 3. Connect lock cylinder to latch rod to the latch. 4. Connect lock button to latch rod to the latch. 5. Position latch in door. 6. Install screws attaching latch to door shut face and tighten to 10 Nm (85 in. lbs.). 7. Connect outside handle to latch rod to the latch. 8. Connect wire harness connector for power door locks if equipped. 9. Install rearward glass run channel. 10. Reposition water dam. 11. Install door trim panel. 12. Adjust outside handle if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig.12 Door Trim Panel Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6200 Fig.13 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6201 Fig.15 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. Fig.16 Power Door Lock/Window Connector 8. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 9. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. Engage clips attaching power window/lock switch panel to door trim panel. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to glass regulator arm. 3. Remove inner door belt weatherstrip. 4. Remove outer door belt weatherstrip. 5. Lower glass to full down position and align glass regulator arm with access holes in inner door panel. 6. Remove front glass run channel. 7. Remove nuts attaching glass channel to regulator arm. 8. Separate glass from regulator arm. 9. Lift glass upward and out of opening at top of door. INSTALLATION 1. Slowly lower glass into door. 2. Position glass in regulator arm. 3. Install front glass run channel. 4. Install nuts attaching glass channel to regulator arm and tighten to 9 Nm (80 in. lbs.). 5. Ensure glass is aligned in run channels and tighten run channel bolts to 9 Nm (80 in. lbs.). 6. Install outer door belt weatherstrip. 7. Install inner door belt weatherstrip. 8. Reposition the water dam. 9. Install door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to access window regulator. 3. Remove glass from door. Fig.34 Power Regulator 4. Disengage power window motor wire connector from door harness, if equipped. Fig. 39 Power Regulator Bolts 5. Loosen bolts in slotted holes attaching regulator to door inner panel. 6. Remove bolts attaching window regulator to inner door panel. 7. Extract window regulator through access hole in inner door panel. 8. Separate window regulator from door panel. INSTALLATION 1. Position regulator in door and align bolts with slotted holes in door inner panel. 2. Install bolts attaching window regulator to inner door panel. 3. Engage power window motor wire connector to door harness, if equipped. 4. Install glass in door. 5. Install outer belt weatherstrip. 6. Install inner belt weatherstrip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 6208 7. Install water dam. 8. Install door trim panel. 9. Verify operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE Removal 1. Remove trim panel. 2. Peel back waterdam to access outside handle. 3. Remove glass run channel. 4. Disconnect latch rod. 5. Remove nuts attaching handle to outer door panel. 6. Separate outside handle from rear door. Installation 1. Position outside handle in rear door. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 6214 2. Install nuts attaching handle to outer door panel. 3. Connect latch rod. 4. Install glass run channel. 5. Reposition the waterdam. 6. Install trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair REMOVAL 1. Remove trim panel. 2. Peel waterdam back to access latch. 3. Disconnect latch rods from latch. 4. Disconnect the latch harness connector. 5. Remove screws attaching latch to rear door. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 6218 INSTALLATION 1. Connect the latch harness connector. 2. Install screws attaching latch to rear door and tighten to 10 Nm (85 in. lbs.). 3. Connect latch rods to latch. 4. Reposition the waterdam. 5. Install trim panel. 6. Adjust the latch if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL REMOVAL 1. Release door latch and open door 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 6222 Fig. 11 Power Window/Lock Connector 7. Disconnect power window/lock harness connector, if equipped. 8. Separate door trim panel from vehicle. 9. If necessary; pull upper trim extension outward to disengage from rear door. INSTALLATION 1. If removed, install upper trim extension on rear door. 2. Position trim panel at door. 3. Engage harness connector for power window/lock, if equipped. 4. Engage inside handle linkage rod to inside handle. 5. Align trim panel retainer steps with inner door panel and slide trim panel into place. 6. Install screws attaching trim panel to door. 7. Install window crank, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove inner beltline weatherstrip. 2. Remove outer beltline weatherstrip. 3. Remove the door waterdam. 4. Lower the window glass enough to access the regulator bolt. 5. Remove the window glass to regulator bolts. 6. Raise the window glass manually. 7. Remove the front lower glass run channel. 8. Lower the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 6226 9. Using a trim stick C-4755 or equivalent, pry up the inside edge of the quarter glass trim. 10. Partially remove front upper window weatherstrip. 11. Raise the glass and remove. INSTALLATION 1. Lower the glass into the door. 2. Install the front glass weatherstrip and the quarter glass trim. 3. Raise the glass manually and secure in the door frame. 4. Install the front lower glass channel. 5. Lower the glass, install the regulator bolts and tighten to 9 Nm (80 in. lbs.). 6. Cycle the glass to ensure proper operation. 7. Install the outer belt weatherstrip. 8. Install the inner belt weatherstrip. 9. Install the waterdam. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove the door inner trim panel. 2. Remove the door waterdam and speaker, if equipped. 3. Remove the inner and outer beltline weatherstrip. 4. Lower the door glass. 5. Remove the bolts attaching the regulator to the glass. 6. Raise the glass manually and secure in the door frame. 7. Loosen the regulator attachment nuts and remove the regulator attachment bolts. 8. Disengage regulator wire harness. Fig. 13 Rear Door Window Regulator 9. Remove the regulator. INSTALLATION 1. Position the window regulator in the door. 2. Install the fasteners attaching the regulator to the inner door panel. 3. Engage the regulator wire harness. 4. Lower the glass manually and install the bolts attaching the regulator to the glass. 5. Cycle the glass to ensure correct operation. 6. Install the inner and outer beltline weatherstrip. 7. Install the door waterdam and radio speaker, if equipped. 8. Install the door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Left Rear Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Fuel Tank Skid Plate Skid Plate: Service and Repair Fuel Tank Skid Plate FUEL TANK SKID PLATE REMOVAL 1. Position a support under the skid plate. Fig. 8 2. Remove the nuts that attach the skid plate to the fuel tank crossmember and the frame crossmember (Fig. 8). 3. Remove the screws that attach the skid plate to the support bracket and the frame side rail. 4. Remove the skid plate from the vehicle. INSTALLATION 1. Position and support the skid plate under the fuel tank. 2. Install the nuts to attach the skid plate to the fuel tank crossmember and the frame crossmember and tighten to 41 N.m (30 ft.lbs.). 3. Install the screws to attach the skid plate to the frame side rail and the support bracket and tighten to 23 N.m (17 ft.lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Fuel Tank Skid Plate > Page 6239 Skid Plate: Service and Repair Transfer Case Skid Plate TRANSFER CASE SKID PLATE REMOVAL 1. Remove the front skid plate. Fig. 11 2. Remove the rear bolts and remove the skid plate. (Fig. 11) INSTALLATION 1. Position skid plate on vehicle. 2. Install two rear bolts and tighten to 40 N.m (30 ft.lbs.). 3. Install the front axle skid plate. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Support trailer hitch on a suitable lifting device. 2. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped. Fig. 9 3. Remove bolts attaching trailer hitch to frame rails (Fig. 9). 4. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rails, remove lifting device and tighten to 108 N.m (80 ft.lbs.). 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Application and ID Console Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overhead Console ............................................................................................................................... .................................................................... 192 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6252 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box GLOVE BOX REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Instrument Cluster Bezel Replacement. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Bezel Replacement 3. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel Replacement. See: Dashboard / Instrument Panel/Service and Repair/Lower Instrument Panel 4. Remove the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. 5. Remove the passenger side end cap from the instrument panel. Refer to Instrument Panel End Cap Replacement. See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel End Cap 6. Remove the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. Fig. 12 Glove Box Remove Install 7. Remove the four screws that secure the bottom of the glove box module to the instrument panel. 8. Unlatch and open the glove box. 9. Remove the latch striker from the upper glove box opening reinforcement. Refer to Glove Box Latch Striker Replacement. See: Glove Box Latch Striker Replacement 10. Remove the two remaining screws that secure the top of the glove box module to the upper glove box opening reinforcement. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6257 Fig. 13 Glove Box Lamp & Switch Connector 11. If the vehicle is equipped with a glove box lamp, pull the glove box module away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 12. Remove the glove box module from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box module to the instrument panel. 2. If the vehicle is equipped with a glove box lamp, reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Position the top of the glove box module to the upper glove box opening reinforcement. 4. Install and tighten the two outboard screws that secure the top of the glove box module to the upper glove box opening reinforcement. Tighten the screws to 2 Nm (20 in. lbs.). 5. Reinstall the glove box latch striker to the upper glove box opening reinforcement. Refer to Glove Box Latch Striker Replacement. See: Glove Box Latch Striker Replacement 6. Close and latch the glove box. 7. Install and tighten the four screws that secure the bottom of the glove box module to the instrument panel. Tighten the screws to 2 Nm (20 in. lbs.) . 8. Install and tighten the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. Tighten the screw to 2 Nm (20 in. lbs.). 9. Reinstall the passenger side end cap onto the instrument panel. Refer to Instrument Panel End Cap Replacement. See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel End Cap 10. Install and tighten the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. Tighten the screw to 2 Nm (20 in. lbs.). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6258 Fig. 15 Glove Box Alignment 11. Open and close the glove box to check for proper hinge operation and alignment. 12. Reinstall the lower bezel onto the instrument panel. Refer to Instrument Panel Lower Bezel Replacement. See: Dashboard / Instrument Panel/Service and Repair/Lower Instrument Panel 13. Reinstall the cluster bezel onto the instrument panel. Refer to Instrument Cluster Bezel Replacement. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Bezel Replacement 14. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6259 Glove Compartment: Service and Repair Glove Box Latch Replacement DISASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for disassembling this component from the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the glove box module from the instrument panel. Refer to Glove Box Replacement. See: Glove Box 2. Remove the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Fig. 14 Glove Box Latch & Handle 3. Remove the glove box bin from the inside of the glove box door. 4. Remove the two screws that secure the glove box latch and handle to the inside of the glove box door. 5. Remove the glove box latch and handle from the inside of the glove box door. ASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for assembling this component to the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box latch and handle to the inside of the glove box door. 2. Install and tighten the two screws that secure the glove box latch and handle to the inside of the glove box door. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the glove box bin to the inside of the glove box door. 4. Install and tighten the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Tighten the screws to 2 Nm (20 in. lbs.). 5. Reinstall the glove box module onto the instrument panel. Refer to Glove Box Replacement. See: Glove Box Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6260 Glove Compartment: Service and Repair Glove Box Latch Striker Replacement GLOVE BOX LATCH STRIKER REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Unlatch and open the glove box. Fig. 16 Glove Box Latch Striker Remove/Install 3. Remove the two screws that secure the latch striker to the upper glove box opening reinforcement. 4. Remove the latch striker from the upper glove box opening reinforcement. INSTALLATION WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discarge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Position the latch striker onto the upper glove box opening reinforcement. 2. Install and tighten the two screws that secure the latch striker to the upper glove box opening reinforcement. Tighten the screws to 2 Nm (20 in. lbs.). 3. Close and latch the glove box. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Trim Panel: Service and Repair Cowl Trim REMOVAL 1. Using a trim stick, pry cowl trim cover from cowl to disengage clips. 2. Separate cowl trim cover from vehicle. INSTALLATION 1. Position cowl trim cover on cowl. 2. Press cowl trim cover into place to engage clips. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 6265 Trim Panel: Service and Repair Front Door Trim Panel TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig.12 Door Trim Panel Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 6266 Fig.13 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 6267 Fig.15 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. Fig.16 Power Door Lock/Window Connector 8. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 9. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. Engage clips attaching power window/lock switch panel to door trim panel. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 6268 Trim Panel: Service and Repair Pillar Trim REMOVAL 1. Remove A-pillar grab handle, if equipped. 2. Remove screws from cowl trim cover. 3. Remove cowl trim cover. 4. Grasp A-pillar trim and pull outward to disengage clips attaching A-pillar trim to A-pillar (Fig. 4). 5. Separate A-pillar trim from vehicle. INSTALLATION 1. Position A-pillar trim at A-pillar, align clips and press into place. 2. Install cowl trim cover. 3. Install A-pillar grab handle, if equipped. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves Door Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6279 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6280 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6281 FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves Door Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6287 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6288 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6289 FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Front Floor NUMBER: 23-010-04 REV. A GROUP: Body DATE: September 9, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND REVISED LABOR OPERATIONS. SUBJECT: Passenger Compartment Floor Water Leak OVERVIEW: This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV sealer. MODELS: 2001-2004 (AN) Dakota **2004 - 2005 (CS) Pacifica** 2001 - 2003 (DN) Durango **2002 - 2005 (KJ) Cherokee (International Markets)** 2001 - 2004 (RS) Caravan, Voyager, Town & Country NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).** SYMPTOM/CONDITION: Water may enter the passenger compartment between the HVAC housing and the bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation from the A/C evaporator can run along the evaporator drain tube and enter the passenger compartment if the seal between the HVAC housing and the bulkhead is not sealed properly. This will result in wet passenger compartment carpet when the air conditioning is operating. DIAGNOSIS: If the symptom exists, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of the opening to seal the joint between the bulkhead and the HVAC gasket and the joint between the drain tube and the HVAC gasket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 6295 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 6301 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations Door Module: Locations A Driver Door Module (DDM) located on the drivers door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 6305 Door Module: Diagrams Driver Door Module C1 (EXcept Base) Driver Door Module C2 (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 6306 Door Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) located on the drivers door trim panel, is used on all models equipped with power locks, power windows, and power mirrors. The DDM can be serviced without removing the front door trim panel. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light- Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module (CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 6307 Door Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Fig.2 Driver Door Module Connector C1 Receptacle Fig.3 Driver Door Module Connector C2 Receptacle Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 6308 Driver Door Module Switch Test (Part 1 Of 2) Driver Door Module Switch Test (Part 2 Of 2) 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 6309 Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair STANDARD PROCEDURE - REMOTE KEYLESS ENTRY TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Power Lock Motor/Ajar Switch (Except Base) Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6319 Power Door Lock Actuator: Description and Operation Models equipped with the optional power lock system have a power operated locking mechanism located within each door. The lock mechanisms are actuated by a reversible electric power lock motor. This motor is integral to the door latch unit within each door. A single short pigtail wire with a molded plastic connector insulator connects each lock motor to the vehicle electrical system through a take out and connector of the wire harness within each door. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the entire door latch unit must be replaced. The driver side front door power lock motor is controlled by a unique driver unlock relay output of the Central Timer Module (CTM), while the remaining power lock motors are all connected in parallel and share common CTM lock and unlock relay outputs. The driver side front door power lock motor also shares the common lock relay output from the CTM. A positive and negative battery connection to the two power lock motor terminals will cause the power lock motor plunger to move in one direction. Reversing the current through these same two connections will cause the power lock motor plunger to move in the opposite direction. The power lock motors and circuits can be tested using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6320 Power Door Lock Actuator: Testing and Inspection Before you proceed with this diagnosis, confirm proper power lock switch, Central Timer Module (CTM), and power lock switch output circuit operation. Remember, the CTM circuitry controls the output to each of the power lock motors. 1. Check each power lock motor for correct operation while moving the power lock switch to both the Lock and Unlock positions. If all of the power lock motors are inoperative, go to Step 2. If one power lock motor is inoperative, go to Step 3. 2. If all of the power lock motors are inoperative, the problem may be caused by one shorted motor. Disconnecting a shorted power lock motor from the power lock circuit will allow the good power lock motor to operate. Disconnect the wire harness connector from each power lock motor, one at a time, and recheck both the lock and unlock functions by operating the power lock switch. If all of the power lock motors are still inoperative after the above test, check for a short or open circuit between the power lock motors and the CTM. If disconnecting one power lock motor causes the other motors to become functional, go to Step 3 to test the disconnected motor. 3. Once it has been determined which power lock motor is inoperative, that motor can be tested as follows. Disconnect the wire harness connector from the inoperative power lock motor. Apply 12 volts to the lock and unlock driver circuit cavities of the power lock motor pigtail wire connector to check its operation in one direction. Reverse the polarity to check the motor operation in the opposite direction. If OK, repair the shorted or open lock or unlock driver circuits between the power lock motor and the CTM as required. If not OK, replace the faulty power lock motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6324 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the ON position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6325 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 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. 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. Fig.5 Power Lock 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6326 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation HEATED MIRRORS The optional heated mirror system only operates in concert with the rear defogger system, and will be automatically turned OFF after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned on again during the same ignition cycle, the heated mirror system will automatically turn OFF after about ten minutes. The heated mirror system will automatically shut OFF if the ignition switch is turned to the OFF position, or it can be turned OFF manually by depressing the defogger switch a second time. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. The heated mirror system is controlled by a momentary rear window defogger switch in the HVAC Control panel. An amber indicator lamp in the switch control will light to indicate when the defogger system is turned ON. The HVAC control assembly also contains the defogger system control circuitry including the timer logic and the defogger relay The heated mirror system only operates in concert with the rear defogger system, and will be automatically turned OFF after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned on again during the same ignition cycle, the heated mirror system will automatically turn OFF after about ten minutes. The heated mirror system will automatically shut OFF if the ignition switch is turned to the OFF position, or it can be turned OFF manually by depressing the defogger switch a second time. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system. HEATED MIRROR GRID Vehicles equipped with the optional heated mirror system have an electric heating grid located behind the mirror glass of each outside rear view mirror. The heated mirrors are controlled by the rear window defogger switch. Electrical current is directed to the heating grid inside the mirror only when the rear window defogger switch is in the ON position. If the outside mirror heating grids are both inoperative, see Rear Window Defogger System in the Diagnosis and Testing. If only one of the outside mirror heating grids is inoperative(Refer to POWER MIRRORS - DIAGNOSIS AND TESTING). The heating grid behind each outside mirror glass cannot be repaired and, if faulty or damaged, the entire power mirror unit must be replaced(Refer to POWER MIRRORS/SIDEVIEW MIRROR REMOVAL). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 6334 Power Mirror Switch: Service and Repair The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID PAINT CODE Exterior vehicle body colors are identified on the Body Code plate. The plate is located on the floor pan under the passenger seat or attached to the front face of the radiator closure panel. The paint code is also identified on the Vehicle Safety Certification Label which is located on the drivers door shut face. The color names provided in the Paint and Trim Code Description chart are the color names used on most repair product containers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations Door Module: Locations A Driver Door Module (DDM) located on the drivers door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 6343 Door Module: Diagrams Driver Door Module C1 (EXcept Base) Driver Door Module C2 (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 6344 Door Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) located on the drivers door trim panel, is used on all models equipped with power locks, power windows, and power mirrors. The DDM can be serviced without removing the front door trim panel. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light- Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module (CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 6345 Door Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Fig.2 Driver Door Module Connector C1 Receptacle Fig.3 Driver Door Module Connector C2 Receptacle Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 6346 Driver Door Module Switch Test (Part 1 Of 2) Driver Door Module Switch Test (Part 2 Of 2) 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 6347 Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions Roof and Associated Components: Service and Repair Safety Precautions CAUTION All SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in nonautomotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product. Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service produces recommended and described in this publication were developed for professional service personnel, and are effective methods for performing vehicle repair. Following these procedures will help ensure efficient economical vehicle performance and service reliability. Some service procedures require the use of special tools designed for specific proceedures. These special tools should he used as recommended throughout this publication. Special attention should be exercised when working with spring-or tension-loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc, since careless removal may cause personal injury. Always wear safety goggles when working on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings. These should be read carefully in order to minimize risk of personal jury or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended. DaimlerChiysler Corporation cannot possibly know, evaluate, and advise the service trade of all conceivable ways in which service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler has not undertaken any such broad service review. Accordingly, anyone uses a service procedure or tool that is not recommended in this publication must be ceitain that neither personal safety, nor vehicle safety, will be jeopardized by the service methods they select. Safety Precautions Adhesives: ^ Adhesives must comply with all federal, state, and local regulations. ^ Material Safety Data Sheets (MSDS) must be available and understood before adhesives are handled ^ All personnel should be instructed in the proper procedures to prevent skin contact with solvents, curing agents, and uncured base adhesives, which could cause allergic reactions or sensitization. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6352 Roof and Associated Components: Service and Repair Introduction Introduction With the new structural adhesives available today, sheet metal repairs are much easier. The corrosion repairs that previously required welding no longer require welding. The day of the worped or oil canned door or quarter panel is over. Structural adhesive can also be used to bridge new and old quarter panel sections using a backer panel at the joint. In addition, this sectioning would be supported with STRSW weld bonding at the pinch weld flange. Fatigued sheet metal can be repaired using structural adhesive as a sandwiching type reinforcement material between the old fatigued panel and a new panel used as reinforcement. Clamps, weights or similar fixtures provide the best method for securing adhesive bonded metal panels. However, screws may be necessary in hard to clamp locations. The use of screws should be limited to these difficult areas only, as cosmetic filling of these holes may present some challenges. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6353 Roof and Associated Components: Service and Repair Types of Structural Adhesive Types of Structural Adhesive Overview: There are three basic chemistries used in aftermarket structural bonding and repair: ^ Epoxy, urethane, and Acrylic. To achieve optimum results, it is best to use the chemistry that bonds best to the substrate to be repaired, is easiest to use, and offers the most permanent, non-detectable repair at the lowest overall repair cost. All three chemistries have their strengths and vveaknesses. ^ Epoxy adhesives bond well to rigid and semi rigid plastics and are generally easy to sand and featheredge. Some may be too rigid for flexible substrates and they often require primers on most bare metal applications. Epoxies can be heat cured to increase strength and accelerate the curing process and have a very stable long shelf life. The mix ratio can vary by +/- 5O% and still cure, however, the performance properties will vary when the mix ratio is off. Epoxies are more forgiving than urethanes with regards to mix ratio accuracy. ^ Acrylic adhesives bond all types of bare metals and are excellent for cross bonding aluminum to steel. They have good NVH properties and some offer anti-corrosion properties so primer on hare metal are not necessary. Most acrylics have a fast room temperature cure, and are stable with regards to temperature and moisture during cure. However, both of these can effect shelf life Mix ratio is modestly important although the performance properties can vary some with a change in mix ratio. Acrylics are the most forgiving of the three chemistries with regards to mix ratio accuracy ^ Urethane adhesives are typically flexible and bond well to plastics. However they usually require primers on metal surfaces to protect against corrosion. Urethanes have good seam sealing and NVH qualities and are frequently the optimal choice for seam scalers. They are sensitive to moisture during cure, packaging and storage. ^ One component urethanes usually have a much shorter shelf life than two component urethanes. Mix ratio is critical for urethanes. In most cases it cannot vary more than +/- 5%. Therefore, hand mixing is not recommended. Urethanes are the most unforgiving of the three chemistries with regards to mix ratio accuracy. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6354 Roof and Associated Components: Service and Repair Joints and Sections Joint and Sections Overlap Joint Overview: This procedure can be used when panel sectioning is being performed on a door skin at the window belt line section. It is also a great procedure for a patch panel being used for corrosion perforation. If using during an OEM panel replacement such as a quarter panel, side aperture on a mini van, or rocker panel you must also use weld bonding at the pinch weld flange area. Illustration A Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6355 Illustration B Preparation: 1. All paint, primer, adhesive, and any other corrosion protection coatings must be removed from the two mating surfaces prior to application. Grind a 2.5cm (1 inch) contact area on both panels where you will do your overlap bond. The metal should be bare and shiny in appearance. Note: Apply the structural adhesive to all bare metal at the bond locations. The adhesive has corrosion resistant properties built-in to protect the metal from corrosion. 2. Pre-bevel to 10 degrees the outer side of the section joint edge of the new panel (See Illustration A) 3. Pre-fit the new panel to ensure proper alignment. If screws will be required to hold the panel in place during curing apply them now to ensure proper fit later. 4. Dispense a small amount of Mopar (part # 05083855AA)/ Fusor #112B structural adhesive from the cartridge to ensure an even flow of both components. Attach a mixing tip and dispense a mixer's length of the adhesive from the cartridge. Note: You will have approximately 70 minutes @ 21°C (70°F) to apply the adhesive and assemble the components. Application: 1. Apply a 3/8 to 1/2 inch bead of Mopar (part # 05083855AA) / Fusor #112B structural adhesive to the mating surfaces. Evenly apply the adhesive over the complete bonding surface making sure not to leave any bare metal. 2. Position the new panel making sure not to lift up on it as lifting will create air bubbles and weaken the bond. Adjustments to the panel fit must be made by sliding, not lifting. 3. Clamp tightly and evenly. There are glass beads in the adhesive that will prevent complete squeeze out. Apply screws in hard-to-clamp areas. Remove excess adhesive from all joints prior to adhesive cure. 4. Allow the adhesive to cure. The Mopar / Fusor #112B structural adhesive takes approximately two to two and a half hours to reach handling strength. The Mopar / Fusor #112B fully cures in approximately eight hours. Expect the adhesive to be a little "tacky" on the surface. This is a normal property of the adhesive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6356 5. Remove clamps and screws. All excess adhesive must be removed from the cosmetic repair area prior to doing any finish work. This will prevent more work later. 6. Bevel the center of the screw-holes and apply fiber-filled waterproof body filler to the screw holes and section seam, complete the repair using conventional body filler. Block sand, prime and paint per paint manufacturer's recommendations. Joint Using a Backer Panel Overview: Backer panel procedures can be used to achieve a smooth joint between panel sections. The backer panel section is good for locations when you don't have the room to smooth an overlap joint. An example would be a corrosion perforation hole in a roof panel. The backer panel joint is a common repair for rocker panel or lower quarter panel sections. When using backer panels on rocker or lower quarter panels all pinch weld locations must be weld/bonded, Refer to The Chrysler Group's Weld Bond publication, part number 81-170-03005 for additional information. Preparation: 1. The original panel joint edge must be pre-beveled to 10 degrees (See Illustration C). 2. All paint, primer, adhesive, and any other corrosion protective coatings must be removed from all mating surfaces prior to application of the adhesive. Grind a 2.5cm (1 inch) contact area on all panels where you will do your backer panel bonding. The metal should be bare and shiny in appearance. The backer panels must also be free of all coatings. Bevel the backer panel edges to prevent moisture or condensation from collecting between the backer and outer panel. (See Illustration C). Note: Apply the structural adhesive to all bare metal at the bond locations. The adhesive has corrosion resistant properties built-in to protect the metal from corrosion. 3. Pre-fit the backer panels to both panels being joined to ensure a proper fit. If screws will be used to hold the panel in place during curing, dry fit them now to ensure proper fit later. Note: 2.5cm (1 inch) overlap of bonded area is recommended. 4. Dispense a small amount of Mopar (part # 05083855AA) / Fusor #112B Structural Adhesive from the cartridge to ensure an even flow of both components. Attach a mixing tip and dispense a mixer's length of the adhesive. Application: 1. Apply a 3/8 to 1/2 inch bead of Mopar / Fusor #112B structural adhesive to the bare metal mating surfaces (Backer Panels). 2. Position the backer panel against the underside of the original panel. Remember do not separate the panels once positioned together, slide the panel for proper alignment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6357 Illustration C 3. If working on a rocker panel, lower quarter panel, or other location with limited access for clamping, use screws to hold the panels together during te curing process Remove all adhesive squeeze out before it cures. 4. Allow the adhesive to cure approximately two to two and a half hours to reach handling strength. The Mopar / Fusor #112B fully cures in approximately eight hours. Expect the adhesive to be a little "tacky" on the surface once cured. This is a normal property of this adhesive. 5. Remove the clamps and/or screws. If screws must be used in a cosmetic area, all excess adhesive must be removed. 6. Bevel the screw-holes and prepare the joint and screw holes for the application of waterproof fiber-filled body filler. Complete the repair using conventional body filler. 7. Refinish following paint manufacturer's recommendation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6358 Roof and Associated Components: Service and Repair Safety Precautions CAUTION All SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in nonautomotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product. Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service produces recommended and described in this publication were developed for professional service personnel, and are effective methods for performing vehicle repair. Following these procedures will help ensure efficient economical vehicle performance and service reliability. Some service procedures require the use of special tools designed for specific proceedures. These special tools should he used as recommended throughout this publication. Special attention should be exercised when working with spring-or tension-loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc, since careless removal may cause personal injury. Always wear safety goggles when working on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings. These should be read carefully in order to minimize risk of personal jury or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended. DaimlerChiysler Corporation cannot possibly know, evaluate, and advise the service trade of all conceivable ways in which service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler has not undertaken any such broad service review. Accordingly, anyone uses a service procedure or tool that is not recommended in this publication must be ceitain that neither personal safety, nor vehicle safety, will be jeopardized by the service methods they select. Safety Precautions Adhesives: ^ Adhesives must comply with all federal, state, and local regulations. ^ Material Safety Data Sheets (MSDS) must be available and understood before adhesives are handled ^ All personnel should be instructed in the proper procedures to prevent skin contact with solvents, curing agents, and uncured base adhesives, which could cause allergic reactions or sensitization. Introduction Introduction With the new structural adhesives available today, sheet metal repairs are much easier. The corrosion repairs that previously required welding no longer require welding. The day of the worped or oil canned door or quarter panel is over. Structural adhesive can also be used to bridge new and old quarter panel sections using a backer panel at the joint. In addition, this sectioning would be supported with STRSW weld bonding at the pinch weld flange. Fatigued sheet metal can be repaired using structural adhesive as a sandwiching type reinforcement material between the old fatigued panel and a new panel used as reinforcement. Clamps, weights or similar fixtures provide the best method for securing adhesive bonded metal panels. However, screws may be necessary in hard to clamp locations. The use of screws should be limited to these difficult areas only, as cosmetic filling of these holes may present some challenges. Types of Structural Adhesive Types of Structural Adhesive Overview: There are three basic chemistries used in aftermarket structural bonding and repair: ^ Epoxy, urethane, and Acrylic. To achieve optimum results, it is best to use the chemistry that bonds best to the substrate to be repaired, is easiest to use, and offers the most permanent, non-detectable repair at the lowest overall repair cost. All three chemistries have their strengths and vveaknesses. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6359 ^ Epoxy adhesives bond well to rigid and semi rigid plastics and are generally easy to sand and featheredge. Some may be too rigid for flexible substrates and they often require primers on most bare metal applications. Epoxies can be heat cured to increase strength and accelerate the curing process and have a very stable long shelf life. The mix ratio can vary by +/- 5O% and still cure, however, the performance properties will vary when the mix ratio is off. Epoxies are more forgiving than urethanes with regards to mix ratio accuracy. ^ Acrylic adhesives bond all types of bare metals and are excellent for cross bonding aluminum to steel. They have good NVH properties and some offer anti-corrosion properties so primer on hare metal are not necessary. Most acrylics have a fast room temperature cure, and are stable with regards to temperature and moisture during cure. However, both of these can effect shelf life Mix ratio is modestly important although the performance properties can vary some with a change in mix ratio. Acrylics are the most forgiving of the three chemistries with regards to mix ratio accuracy ^ Urethane adhesives are typically flexible and bond well to plastics. However they usually require primers on metal surfaces to protect against corrosion. Urethanes have good seam sealing and NVH qualities and are frequently the optimal choice for seam scalers. They are sensitive to moisture during cure, packaging and storage. ^ One component urethanes usually have a much shorter shelf life than two component urethanes. Mix ratio is critical for urethanes. In most cases it cannot vary more than +/- 5%. Therefore, hand mixing is not recommended. Urethanes are the most unforgiving of the three chemistries with regards to mix ratio accuracy. Joints and Sections Joint and Sections Overlap Joint Overview: This procedure can be used when panel sectioning is being performed on a door skin at the window belt line section. It is also a great procedure for a patch panel being used for corrosion perforation. If using during an OEM panel replacement such as a quarter panel, side aperture on a mini van, or rocker panel you must also use weld bonding at the pinch weld flange area. Illustration A Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6360 Illustration B Preparation: 1. All paint, primer, adhesive, and any other corrosion protection coatings must be removed from the two mating surfaces prior to application. Grind a 2.5cm (1 inch) contact area on both panels where you will do your overlap bond. The metal should be bare and shiny in appearance. Note: Apply the structural adhesive to all bare metal at the bond locations. The adhesive has corrosion resistant properties built-in to protect the metal from corrosion. 2. Pre-bevel to 10 degrees the outer side of the section joint edge of the new panel (See Illustration A) 3. Pre-fit the new panel to ensure proper alignment. If screws will be required to hold the panel in place during curing apply them now to ensure proper fit later. 4. Dispense a small amount of Mopar (part # 05083855AA)/ Fusor #112B structural adhesive from the cartridge to ensure an even flow of both components. Attach a mixing tip and dispense a mixer's length of the adhesive from the cartridge. Note: You will have approximately 70 minutes @ 21°C (70°F) to apply the adhesive and assemble the components. Application: 1. Apply a 3/8 to 1/2 inch bead of Mopar (part # 05083855AA) / Fusor #112B structural adhesive to the mating surfaces. Evenly apply the adhesive over the complete bonding surface making sure not to leave any bare metal. 2. Position the new panel making sure not to lift up on it as lifting will create air bubbles and weaken the bond. Adjustments to the panel fit must be made by sliding, not lifting. 3. Clamp tightly and evenly. There are glass beads in the adhesive that will prevent complete squeeze out. Apply screws in hard-to-clamp areas. Remove excess adhesive from all joints prior to adhesive cure. 4. Allow the adhesive to cure. The Mopar / Fusor #112B structural adhesive takes approximately two to two and a half hours to reach handling strength. The Mopar / Fusor #112B fully cures in approximately eight hours. Expect the adhesive to be a little "tacky" on the surface. This is a normal property of the adhesive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6361 5. Remove clamps and screws. All excess adhesive must be removed from the cosmetic repair area prior to doing any finish work. This will prevent more work later. 6. Bevel the center of the screw-holes and apply fiber-filled waterproof body filler to the screw holes and section seam, complete the repair using conventional body filler. Block sand, prime and paint per paint manufacturer's recommendations. Joint Using a Backer Panel Overview: Backer panel procedures can be used to achieve a smooth joint between panel sections. The backer panel section is good for locations when you don't have the room to smooth an overlap joint. An example would be a corrosion perforation hole in a roof panel. The backer panel joint is a common repair for rocker panel or lower quarter panel sections. When using backer panels on rocker or lower quarter panels all pinch weld locations must be weld/bonded, Refer to The Chrysler Group's Weld Bond publication, part number 81-170-03005 for additional information. Preparation: 1. The original panel joint edge must be pre-beveled to 10 degrees (See Illustration C). 2. All paint, primer, adhesive, and any other corrosion protective coatings must be removed from all mating surfaces prior to application of the adhesive. Grind a 2.5cm (1 inch) contact area on all panels where you will do your backer panel bonding. The metal should be bare and shiny in appearance. The backer panels must also be free of all coatings. Bevel the backer panel edges to prevent moisture or condensation from collecting between the backer and outer panel. (See Illustration C). Note: Apply the structural adhesive to all bare metal at the bond locations. The adhesive has corrosion resistant properties built-in to protect the metal from corrosion. 3. Pre-fit the backer panels to both panels being joined to ensure a proper fit. If screws will be used to hold the panel in place during curing, dry fit them now to ensure proper fit later. Note: 2.5cm (1 inch) overlap of bonded area is recommended. 4. Dispense a small amount of Mopar (part # 05083855AA) / Fusor #112B Structural Adhesive from the cartridge to ensure an even flow of both components. Attach a mixing tip and dispense a mixer's length of the adhesive. Application: 1. Apply a 3/8 to 1/2 inch bead of Mopar / Fusor #112B structural adhesive to the bare metal mating surfaces (Backer Panels). 2. Position the backer panel against the underside of the original panel. Remember do not separate the panels once positioned together, slide the panel for proper alignment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6362 Illustration C 3. If working on a rocker panel, lower quarter panel, or other location with limited access for clamping, use screws to hold the panels together during te curing process Remove all adhesive squeeze out before it cures. 4. Allow the adhesive to cure approximately two to two and a half hours to reach handling strength. The Mopar / Fusor #112B fully cures in approximately eight hours. Expect the adhesive to be a little "tacky" on the surface once cured. This is a normal property of this adhesive. 5. Remove the clamps and/or screws. If screws must be used in a cosmetic area, all excess adhesive must be removed. 6. Bevel the screw-holes and prepare the joint and screw holes for the application of waterproof fiber-filled body filler. Complete the repair using conventional body filler. 7. Refinish following paint manufacturer's recommendation. Corrosion Corrosion Overview: There are certain rule of thumb conditions when repairing any type of corrosion: All rust / corrosion must be removed or it will return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6363 Sand blasting / grinding will remove surface rust but it won't remove rust from deep in the pitting. Any bare metal around the repair must have a corrosion resistant material applied to protect against future corrosion. Note: Most corrosion removing I neutralizing chemicals have safety / health concerns. Always follow manufacturer's recommendations when using corrosion removal equipment and chemicals. Corrosion Perforation Corrosion Preforation Overview: Corrosion perforation is any hole that has formed because of a corrosion condition When repairing corrosion perforation you must remove all corrosion prior to beginning the repair. A cosmetic body panel does not require replacement in all cases of perforation. A new partial panel can be hand crafted or cut from an OE panel to accomplish a good lasting repair Corrosion perforation can be repaired using a repair panel and the overlap process or the backer panel process. The type of section to be used is usually determined by the location of the condition. A lower quarter panel can usually be repaired using the overlap procedure. On the other hand, using a backer panel to repair corrosion on the roof would be a better choice. Areas like a roof, which require a smoother transition of the new replacement panel and the existing panel, the backer process usually works better. Roof Panel Repair Roof Panel Repair Overview: When evaluating a corrosion condition on a roof panel you need to take into consideration things like extent of the condition. Will you need to remove the windshield to do the repair? Can a repair be made without removing the headliner? What type of joint would be best suited for this particular repair? Roof Panel Repair using a Backer Panel: 1. Remove all parts necessary to access the damaged area. 2. Remove all the corrosion from the panel being repaired. If there is any corrosion left behind, even if it's deep in the pitted areas the corrosion will return. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6364 Illustration D 3. All paint, primer, adhesive, and any other protective coatings must be removed from all mating surfaces prior to application of any adhesive for the backer panels. Grind a 2.5cm (1 inch) contact area on all panels where you will do your backer panel bond. The metal should be bare and shiny in appearance. The panels to be used as the backer panels must also be free of all coatings. Bevel the backer panel to prevent moisture or condensation from collecting between the panels. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6365 Illustration E 4. Pre-fit the backer panels to the roof and the insert patch to ensure a proper fit. If screws Will be required to hold the backer panels and the inseit in place during application they Should be used during the dry fit. 5. Using Mopar (part # 05083855AA) / Fusor #112B dispense a small amount of adhesive with out the tip to assure there is an even flow of adhesive from booth sides of the cartndge. Once you are sure there is even flow install the mixing tip and pump the adhesive through the mixing tip. Note: Apply the structural adhesive to all bare metal at the bond area The adhesive has corrosion resistant properties built-in to protect the metal from corrosion. 6. Apply 3/8 to 1/2 inch of Mopar / Fusor #112B to the mounting area of the insert panels. From this point you will have approximately 70 minutes @ 21 °C (70 °F) to apply the adhesive and assemble the components. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6366 Illustration F 7. Use a body filler applicator to smooth the adhesive and to cover all bare metal to prevent conosion. 8. Position the backer panels into place using the clamps and/or screws from the prior dry fit process. 9. You may need to smooth or finesse the adhesive at the bond surface prior to installing the insert/repair panel. 10. Apply a small amount of adhesive to the underside of the insert/repair panel at the bare metal spots to ensure there will be corrosion protection. 11. Secure the insert/repair panel in place tising clamps and/or screws from the dry fit process. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6367 12. Remove all excess adhesive material from the work area. 13. Once the adhesive has achieved handling strength in approximately 2 1/2 hours remove the clamps and/or screws. 14. When the adhesive has reached full cure, if screws were used bevel the screw-holes and prepare the joint and screw holes for the application of waterproof fiber-filled body filler. Complete repair using conventional body filler. 15. Refinish following paint manufacturers recommendations. Hem Flange Corrosion Hem Flange Corrosion Overview: Hem flange corrosion generally starts at the bottom of a down standing hem flange where water can collect. The condition can occur on hoods, liftgates, and door skins. The condition usually begins where the outer panel makes the turn upward to form the hem flange on the inside of the panel. The condition can vary from minor surface corrosion to perforation. The repair process will vaiy based on the severity of the condition. Hem Flange Repair: Overview: When the condition is surface rust at the edge of the hem you would remove the corrosion, and apply a corrosion resistant primer. Seal the hem edge using seam sealer and topcoat following paint suppliers recommendations. A slightly more aggressive corrosion condition may require opening of the hem to remove all the corrosion. Once the hem is opened you must remove all the corrosion and apply a corrosion resistant material to protect the sheet metal. A couple of the most common corrosion resistant primers are acid etch primers and epoxy primers. The adhesive The Chrysler Group recommends for hem repairs contains corosion resistant properties (built in) so no primer is required. Once the corrosion is removed from the hem area apply the Mopar / Fusor #112B adhesive, follow the directions that are supplied with the adhesive. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6368 Move the hem back into place remove any excessive adhesive squeeze-out. After the adhesive has cured finish sand, prime, seam seal and paint. Hem Flange Removal Repair: Overview: In cases where there are parts of the hem missing or the hem is very thin it may be easier to remove the hem completely to achieve an acceptable repair. The outer door skin is bonded to the inner door structure around the perimeter of the door assembly. The hem is applied during the assembly process to hold the inner and outer door panels together until the adhesive is cured using heat from the paint process. Once the adhesive is cured there is no need for a full hem flange. 1. Use a grinder equipped with a 36 grit-grinding disc to remove the hem flange by grinding through the lower edge of the door skin. To do this you must use the grinder so the rotation of the grinding disc moves inward toward the inside of the vehicle at the cutting surface. If the grinding disc moves outward away from the door skin on the cutting edge you will peel the outer door skin away from the inner door causing damage to the skin. 2. Once you have cut through the skin, peel the remaining hem from the inner door. 3. Check the bond between the inner and outer door panels, at the bottom of the door if there are locations that require adhesive bonding use Mopar (part 05083S55AA) / Fusor #112B structural adhesive. Follow the information on the instruction sheet for curing and work time. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > System Information > Service and Repair > Safety Precautions > Page 6369 Illustration H Note: There must be drain holes in the bottom of the door. If you apply adhesive to the bottom of the door make sure to you have a drain hole at the front and rear of the door. 4. finish sand, prime, and topcoat per paint supplier's recommendation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motors Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the outboard side of the seat cushion side shield. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6377 Power Seat Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6378 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch The switch is located on the outboard side of the seat cushion side shield. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6379 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Refer to the procedure. Fig.1 Power Seat Switch Continuity Test 3. With assistance from another person, use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch schematic and Continuity chart . If OK, see the Power Seat Track Diagnosis and Testing procedure. If not OK, replace the faulty power seat switch unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6380 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the two screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. INSTALLATION 1. Install the two screws that secure the power seat switch to the inside of the seat cushion side shield. 2. Install the wire harness connector on the power seat switch module. 3. Install the seat cushion side shield and power seat switch module on the seat as a unit. Refer to Body for the procedure. 4. Install the recliner lever on the recliner mechanism release shaft. 5. Install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 6. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation Vehicles equipped with the power seat option, utilize a power seat track. Three reversible DC motors are incorporated into the power seat track. The motors are connected to worm-drive gearboxes that move the seat track through a combination of screw-type drive units. The front and rear of the seat are operated by different motors. They can be raised or lowered independently of each other. When the center power seat switch is pushed in the Up or Down direction, both the front and rear motors operate in unison. Each motor contains a self-resetting circuit breaker to protect it from overload. Consecutive or frequent resetting of the circuit breakers must not be allowed to continue, or the motors may be damaged. The power seat track cannot be repaired, and is serviced only as a complete assembly. If any component in this assembly is faulty or damaged, the entire power seat track must be replaced. When a power seat switch is actuated, a battery feed and a ground path are applied through the power seat switch contacts to the appropriate motor or motors. The motor and drive unit operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat track is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor is reversed through the switch contacts. This causes the motor to run in the opposite direction. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 6384 Seat Track: Testing and Inspection Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction, refer to Diagnosis and Testing of the Power Seat Switch. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the power distribution center. If OK, go to Step 2. If not OK, replace the faulty fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the power distribution center as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch as described. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power seat track (adjuster) assembly If the circuits are not OK, repair the wire harness as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 6385 Seat Track: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side seat assembly from the vehicle. 3. Disconnect the power seat wire harness connectors. 4. Disconnect the power seat wire harness retainers from the seat track assembly. 5. Remove the four bolts that secure the power seat track assembly to the seat cushion frame. 6. If the vehicle is equipped with a split bench seat, remove the fasteners that secure the center seat cushion section to the brackets on the power seat track assembly 7. Remove the power seat track assembly from the seat cushion frame. CAUTION: Before installing the seat into the vehicle, be certain to adjust the seat fully rearward on its tracks. Then install and tighten the front track mounting screws before installing the rear screws or the tracks may be damaged. INSTALLATION 1. Position the power seat track assembly on the seat cushion frame and compare the old and replacement seat tracks to be certain the correct part is available. 2. If the vehicle is equipped with a split bench seat, Install the fasteners that secure the center seat cushion section to the brackets on the power seat track assembly 3. Install the four bolts that secure the power seat track assembly to the seat cushion frame. Torque the bolts to 27 Nm (20 ft. lbs.). 4. Install the power seat wire harness retainers on the seat track assembly. 5. Connect the power seat wire harness connectors. 6. Install the driver side seat assembly in the vehicle. Refer to the Body for the procedure. 7. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch (Except Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6390 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the ON position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6391 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 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. 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. Fig.5 Power Lock 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 Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6392 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 6396 Power Mirror Switch: Service and Repair The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the outboard side of the seat cushion side shield. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 6400 Power Seat Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 6401 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch The switch is located on the outboard side of the seat cushion side shield. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 6402 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Refer to the procedure. Fig.1 Power Seat Switch Continuity Test 3. With assistance from another person, use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch schematic and Continuity chart . If OK, see the Power Seat Track Diagnosis and Testing procedure. If not OK, replace the faulty power seat switch unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 6403 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the two screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. INSTALLATION 1. Install the two screws that secure the power seat switch to the inside of the seat cushion side shield. 2. Install the wire harness connector on the power seat switch module. 3. Install the seat cushion side shield and power seat switch module on the seat as a unit. Refer to Body for the procedure. 4. Install the recliner lever on the recliner mechanism release shaft. 5. Install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 6. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Trunk / Liftgate Switch: Diagrams Left Rear Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair FRONT AIR DAM REMOVAL 1. Raise and support the vehicle. Refer to Vehicle Lifting. Fig. 2a 2. Remove two lower push pin fasteners.(Fig. 2A) 3. Remove screws at wheel wells. Fig. 2b 4. Remove inner support clips at each side.(Fig. 2B) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Page 6411 Fig. 2c 5. Separate the support tabs from fascia.(Fig. 2C) 6. Slide upper air dam lip up off the support clips in fascia. NOTE: Support clips are serviceable by drilling out rivets and installing a new clip with new rivets. INSTALLATION NOTE: Support clips are serviceable by drilling out rivets and installing a new clip with new rivets. 1. Slide upper air dam lip onto support clips. Fig. 2d 2. Position support tabs through slots in fascia starting at front and working around to the side.(Fig. 2D) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Page 6412 Fig. 2e 3. Install support tab clips into the support tabs.(Fig. 2E) 4. Install two screws at wheel wells. 5. Install two lower push pin fasteners. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6422 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6423 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6424 FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6430 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6431 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6432 FAILURE CODE: Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Servo Mounting Bracket-to-Servo Nuts .................................................................................................................................................. 8.5 Nm (75 in. lbs.) Servo Mounting Bracket-to-Body Nuts ....................................................................................................................................... 7 - 10 Nm (63 - 94 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6437 Cruise Control Servo: Locations Fig.6 Speed Control Servo Location Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6438 Speed Control Servo (Except 2.5L) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6439 Cruise Control Servo: Description and Operation The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. The Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph to resume, 35 mph to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6440 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. Fig.6 Speed Control Servo Location 2. Disconnect vacuum hose (line) at servo. 3. Disconnect electrical connector at servo. 4. Disconnect servo cable at throttle body. Refer to Servo Cable Removal/Installation. Fig.7 Servo Cable Clip Remove/Install - Typical 5. Remove 2 mounting nuts holding servo cable sleeve to bracket or. 6. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip and remove clip. Note: The servo mounting bracket displayed in is a typical bracket and may/may not be applicable to this model vehicle. 7. Remove servo from mounting bracket. While removing, note orientation of servo to bracket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6441 INSTALLATION 1. Position servo to mounting bracket. 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install servo mounting nuts and tighten to 8.5 Nm (75 in. lbs.). 5. Connect vacuum line at servo. 6. Connect electrical connector at servo. 7. Connect servo cable to throttle body. Refer to Servo Cable Removal/Installation. 8. Connect negative battery cable to battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6445 Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6446 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove air box housing from throttle body. The accelerator cable must be partially removed to gain access to speed control cable. Fig.3 Cable Connectors At Bell Crank - 4.7L V-8 Engine 3. Using finger pressure only, disconnect accelerator cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. 4. Lift accelerator cable from top of cable cam. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6447 Fig.4 Accelerator Cable Release Tab - 4.7L V-8 Engine 5. Press tab to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount towards passenger side of vehicle to remove cable from bracket. 6. Using finger pressure only, disconnect speed control cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. Fig.5 Speed Control Cable At Bracket - 4.7L V-8 Engine 7. Slide speed control cable plastic mount towards passenger side of vehicle to remove cable from bracket. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6448 8. Remove servo cable from servo. INSTALLATION 1. Install end of cable to speed control servo. 2. Slide speed control cable plastic mount into bracket. 3. Install speed control cable connector onto throttle body bellcrank pin (snaps ON). 4. Slide accelerator cable plastic mount into bracket. Continue sliding until tab is aligned to hole in mounting bracket. 5. Route accelerator cable over top of cable cam. 6. Install accelerator cable connector onto throttle body bellcrank pin (snaps ON). 7. Install air box housing to throttle body 8. Connect negative battery cable at battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6452 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6453 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6454 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6455 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6456 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications Cruise Control Vacuum Reservoir: Specifications Vacuum Reservoir Mounting Bolt .......................................................................................................................................................... 2.2 Nm (20 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6460 Cruise Control Vacuum Reservoir: Locations The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6461 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. The vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6462 Cruise Control Vacuum Reservoir: Testing and Inspection 1. Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected hose. 2. Start engine and observe gauge at idle. Vacuum gauge should read at least ten inches of mercury. 3. If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks. Also check actual engine intake manifold vacuum. If manifold vacuum does not meet this requirement, check for poor engine performance and repair as necessary. 4. If vacuum line to engine is not leaking, check for leak at vacuum reservoir. To locate and gain access to reservoir, refer to Vacuum Reservoir Removal/Installation. Disconnect vacuum line at reservoir and connect a hand-operated vacuum pump to reservoir fitting. Apply vacuum. Reservoir vacuum should not bleed OFF. If vacuum is being lost, replace reservoir. 5. Verify operation of one-way check valve and check it for leaks. a. Locate one-way check valve. The valve is located in vacuum line between vacuum reservoir and engine vacuum source. Disconnect vacuum hoses (lines) at each end of valve. b. Connect a hand-operated vacuum pump to reservoir end of check valve. Apply vacuum. Vacuum should not bleed OFF. If vacuum is being lost, replace one-way check valve. c. Connect a hand-operated vacuum pump to vacuum source end of check valve. Apply vacuum. Vacuum should flow through valve. If vacuum is not flowing, replace one-way check valve. Seal the fitting at opposite end of valve with a finger and apply vacuum. If vacuum will not hold, diaphragm within check valve has ruptured. Replace valve. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6463 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL Fig.9 Vacuum Reservoir Mounting Cowl Plenum Cover/Grille Panel Remove/Install The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield or. 1. Disconnect and isolate negative battery at cable. 2. Remove both windshield wiper arm/blade assemblies. Refer to Wiper and Washer Systems. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6464 Cowl Grille Panel Weather-strip 3. Remove rubber weather-strip at front edge of cowl grill. 4. Remove four plastic nuts securing cowl plenum cover/grille panel to studs on cowl top panel near base of windshield. 5. Remove two plastic rivets securing each side of the cowl plenum cover/grille panel to cowl plenum panel and cowl top panel. 6. Lift cowl plenum cover/grille panel from vehicle far enough to access windshield washer and vacuum plumbing near right end of cowl plenum. 7. Disconnect windshield washer supply hose at in-line connector. 8. Disconnect vacuum supply hose from vacuum supply connector at vacuum reservoir. 9. Remove cowl plenum cover/grille panel from vehicle. 10. Remove three reservoir mounting screws. 11. Remove vacuum reservoir from vehicle. INSTALLATION The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield or. 1. Install vacuum reservoir and three mounting screws to plastic cowl cover. Tighten three screws to 2.2 Nm (20 in. lbs.) torque. 2. Position cowl plenum cover/grille panel to vehicle. 3. Connect vacuum supply hose to vacuum reservoir. 4. Connect windshield washer supply hose at inline connector. 5. Install and tighten cowl cover fasteners to vehicle body. 6. Install rubber weather-strip at front edge of cowl grill. 7. Install windshield wiper arms. Refer to Wiper and Washer Systems. 8. Connect negative battery to cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 in. lbs.) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6469 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6470 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6471 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6472 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6473 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 6478 ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Anti-lock Brake .................................................................................................................................... ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 6479 ABS Light: Description and Operation ABS INDICATOR An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) 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 ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-ON Message - Each time the cluster receives a lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp- OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the CAB for three consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the CAB will store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Chime Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6501 Audible Warning Device: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6502 Audible Warning Device: Description and Operation CHIME WARNING SYSTEM The chime warning system uses a single chime tone generator that is integral to the Central Timer Module (CTM) to provide an audible indication of various vehicle conditions that may require the attention of the vehicle operator. The chime warning system includes the following major components: Central Timer Module - Door Ajar Switch - Headlamp Switch - Ignition Switch The CTM chime warning system circuitry and the integral chime tone generator cannot be adjusted or repaired. If the CTM or the chime tone generator are damaged or faulty, the CTM unit must be replaced. The chime warning system is designed to provide an audible output as an indication of various conditions that may require the attention or awareness of the vehicle operator. The chime warning system components operate on battery current received through a fused B(+) fuse in the Junction Block (JB) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. There are two chime rates: Low: 50 chimes per minute for reminders - High: 180 chimes per minute for serious conditions that require immediate attention The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights or cargo lights are left on. The low rate chime sounds for any of the other conditions. The seat belt warning chime is activated for 6 seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime warning system provides an audible indication to the vehicle operator under the following conditions: Compass/Mini-Trip Computer (CMTC) Reset - The Central Timer Module (CTM) chime tone generator will generate one chime each time a Programmable Communications Interface (PCI) data bus message is received from the optional CMTC indicating that the CMTC has been reset. - Door Ajar Warning - The CTM chime tone generator will generate a chime tone to announce that a hard wired input from any door ajar switch indicates that a door is open with the ignition switch in the ON position and the vehicle speed is 0 mph. - Fasten Seat Belt Warning - The CTM chime generator will generate repetitive chimes to announce that a hard wired input from the seat belt switch to the Electro-Mechanical Instrument Cluster (EMIC) indicates that the driver side front seat belt is not fastened. This chime is based upon a PCI data bus chime request message input to the CTM from the EMIC, but is not tied to the operation of the EMIC "Seatbelt" indicator. - Head/Park/Courtesy Lights ON Warning - The CTM chime tone generator will generate repetitive chimes to announce that hard wired inputs from the driver door ajar switch, headlamp switch, and ignition indicate that the exterior or courtesy lamps are turned ON with the driver side front door opened and the ignition switch in the OFF position. The chimes will continue to sound until the exterior or courtesy lamps are turned OFF, the driver side front door is closed, or the ignition switch is turned to the RUN position. - Key-In-Ignition Warning - The CTM chime tone generator will generate repetitive chimes to announce that hard wired inputs from the driver door ajar switch and ignition indicate that the key is in the ignition with the driver side front door opened and the ignition switch in the OFF or ACC position. The chimes will continue to sound until the key is removed from the ignition, the driver side front door is closed, or the ignition switch is turned to the RUN position. The chime will also sound when the ignition is OFF, the driver's door is open and the headlamps, courtesy lamps or the cargo lamps are on. - Overspeed Warning - The CTM chime tone generator will generate repetitive chime tones at a slow rate to announce that a PCI data bus vehicle speed message from the Powertrain Control Module (PCM) indicates that the vehicle speed is over a programmed speed value. This feature is only enabled on a CTM that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Turn Signal ON Reminder Warning - A turn signal indicator is illuminated after the vehicle has surpassed a programmed speed and distance. The EMIC sends a chime request to the CTM. The chimes will continue to sound until the turn signal is turned OFF. - Warning Chime Support - The CTM chime tone generator will generate a single chime to announce that a PCI data bus chime request message input has been received from the EMIC or the Airbag Control Module (ACM). These chimes provide an audible alert to the vehicle operator that supplements certain visual indications displayed by the EMIC. Supplemented indications include the following: Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check Gauges lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6503 - Low Fuel warning - Low Washer Fluid lamp - Transmission Temperature lamp (automatic transmission only) - ABS light on - Water in fuel (diesel) The CTM provides chime service for all available features in the chime warning system. CTM determines the priority of each chime tone request input that is received, as well as the rate and duration of each chime tone that is to be generated. The hard wired chime warning system inputs to the CTM, as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6504 Audible Warning Device: Testing and Inspection Chime Warning System Diagnosis (Part 1 Of 2) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6505 Chime Warning System Diagnosis (Part 2 Of 2) The hard wired chime warning system inputs to the Central Timer Module (CTM), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Central Timer Module ( CTM ) Low Option: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Central Timer Module ( CTM ) Low Option: Connector Views Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 Central Timer Module ( CTM ) Low Option: Electrical Diagrams System Schematic Wiring Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 8w-45-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 8w-45-3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 8w-45-4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 8w-45-5 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 8w-45-6 (Base/Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 8w-45-7 (Midline/Highline) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 8w-45-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 8w-45-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 8w-45-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 8w-45-11 (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 8w-45-12 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 8w-45-13 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 8w-45-14 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 8w-45-15 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 8w-45-16 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 8w-45-17 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 8w-45-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 8w-45-19 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6549 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6550 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. Fig.1 Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel (Fig. 1). The base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM are used on vehicles that are equipped with one or more of those options. The CTM utilizes circuitry, and information carried on the Programmable Communications Interface (PCI) data bus network, along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Base and Highline CTM supports or controls the following features: Automatic Door Lock - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Low and High Beam Head Lamps - Optical Horn - Park Lamps - Speed Sensitive Intermittent Wiper Controls Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Horn Chirp - Optical Chirp - Panic Mode Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6551 - Power Door Locks - Programmable Features - Remote Keyless Entry - Remote Radio Switch Interface - Vehicle Theft Security System (VTSS) The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Programmable Communications Interface (PCI) data bus to control the volume, seek, and pre-set station advance functions of the optional radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. (Refer to BODY CONTROL/CENTRAL TIMER MODULE - DESCRIPTION) for more information on the high-line CTM. (Refer to REMOTE SWITCHES DESCRIPTION) for more information on this component. In addition, radio receivers connected to the PCI data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB III testing of the audio systems. Hard wired circuitry connects the CTM to the electrical system of the vehicle. Refer to the appropriate wiring information. All versions of the CTM for this model are serviced only as a complete unit. Many of the features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. If any of the CTM hardware components are damaged or faulty the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods. For diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. The Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The programming and all of the inputs allow the CTM to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM then performs those tasks and provides those features through both PCI data bus communication with other modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems. The CTM operates on battery voltage received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (RUN/START) circuit, and a fused ignition switch output (RUN/ACC) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position. The CTM is grounded to the chassis. Two of these ground circuits are on the left inner cowl panel near the CTM, while the third is near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store Diagnostic Trouble Codes (DTC) in memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Cargo lamp switch sense - Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch MUX - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (RUN/ACC) - Fused ignition switch output (RUN/START) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Low beam switch output - Park brake switch sense Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6552 - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch MUX - high line with power locks only - PCI bus circuit - Radio control MUX - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Cargo lamp driver - Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) - Ignition Staus - VTSS Status - Country Code Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6553 Central Timer Module ( CTM ) Low Option: Testing and Inspection The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the modules that provide inputs to, or receive outputs from, the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6554 Central Timer Module ( CTM ) Low Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 6558 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Brake Warning ..................................................................................................................................... ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 6559 Brake Warning Indicator: Description and Operation DESCRIPTION A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. OPERATION The red warning light alerts the driver if a pressure differential exists between the front and rear hydraulic systems or the parking brakes are applied. The lamp is turned on momentarily when the ignition switch is turn to the on position. This is a self test to verify the lamp is operational. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Check Gauges Lamp: Locations The check gauges indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations > Page 6563 Check Gauges Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Gauges ..................................................................................................................................... ................................................................... LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations > Page 6564 Check Gauges Lamp: Description and Operation A check gauges indicator is standard equipment on all instrument clusters The check gauges indicator is located in the Information Center area of the instrument cluster, to the right of center. The check gauges indicator consists of a stencil-like cutout of the words "CHECK GAGES" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "CHECK GAGES" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The check gauges indicator Light Emitting Diode (LED) 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 check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is about 122 °C (253 °F) or higher, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine coolant temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is about 3.45 kPa (0.5 psi) or lower, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 3.45 kPa (0.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator on in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low (Charge Fail) Message - Each time the cluster receives a message from the PCM indicating the electrical system voltage is less than about 11.5 volts (charge fail condition), the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is greater than about 12.0 volts (but less than 16.0 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - System Voltage High Message - Each time the cluster receives a message from the PCM indicating the electrical system voltage is greater than about 16.0 volts, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than about 15.5 volts (but greater than 11.5 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. For further diagnosis of the check gauges indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the check gauges indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Cigarette Lighter: Locations The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Cigar Lighter/Power Outlet Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Cigarette Lighter: Electrical Diagrams 8w-41-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 8w-41-3 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass: Locations The compass mini-trip computer is located in the overhead console on models equipped with this option. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 6592 Compass: Description and Operation COMPASS / MINI-TRIP COMPUTER (CMTC) The Compass/Mini-Trip Computer is located in the overhead console on models equipped with this option. The Compass/Mini-Trip Computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The Compass/Mini-Trip Computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The Compass/Mini-Trip Computer provides several electronic functions and features. Some of the functions and features that the Compass/Mini-Trip Computer module supports and/or controls, include the following display options: Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant Fuel Economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. Elapsed Time (ET) - shows the accumulated ignition-ON time since the last trip computer reset. - Step Button - Press this button to cycle through all the mini-trip computer displays. - US/M Button - Press this button to convert all vehicle displays from US to Metric to US. - Blank Screen - the Compass/Mini-Trip VFD is turned OFF. The ambient temperature sensor is hard wired to the HVAC control head. Data input for all other Compass/Mini-Trip Computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. The Compass/Mini-Trip Computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete Compass/Mini-Trip Computer module must be replaced. The Compass/Mini-Trip Computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the Compass/Mini-Trip Computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the Compass/Mini-Trip Computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This Compass/Mini-Trip Computer features several functions that can be reset. If the RESET push button is depressed for more than 1 second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. For more information on the features and control functions of the Compass/Mini-Trip Computer, see the owner's manual in the vehicle glove box. COMPASS While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 ° turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country; the difference between Magnetic Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 6593 and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately 5 seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. TEMPERATURE The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the ON position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The Compass/Mini-Trip Computer will display mm and max temperatures of -40 °C (-40 °F) and 54 °C (130 °F). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 6594 Compass: Testing and Inspection COMPASS/MINI-TRIP COMPUTER TEST If the problem with the Compass/Mini-Trip Computer module is an inaccurate or scrambled display refer to Self-Diagnostic Test below. If the problem with the Compass/Mini-Trip Computer module is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB scan tool and the proper Diagnostic Procedures manual to test for the correct dimming message inputs being received from the instrument cluster over the J1850 data bus. If the problem is a no-display condition, use the following procedures. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring. 1. Check the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavities of the roof wire harness connector for the overhead console and a good ground. There should be continuity If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the overhead console. If OK, refer to Self-Diagnostic Test below, for further diagnosis of the Compass/Mini-Trip Computer module and the J1850 data bus. If not OK, repair the open fused ignition switch output (run/start) circuit to the junction block as required. SELF-DIAGNOSTIC TEST A self-diagnostic test is used to determine that the Compass/Mini-Trip Computer module is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The Compass/Mini-Trip Computer self - test can also be performed using a DRB III. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the OFF position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/ON position. 2. Continue to hold both buttons depressed until the Compass/Mini-Trip Computer module enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the Compass/Mini-Trip Computer module performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - J1850 Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the Compass/Mini-Trip Computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but Compass/Mini-Trip Computer operation is still improper, the use of a DRB III scan tool and the proper Diagnostic Procedures manual are required for further diagnosis. - If the "FAIL" message is displayed, the Compass/Mini-Trip Computer module is faulty and must be replaced. - If the "PASS" message is displayed, the Compass/Mini-Trip Computer module is OK, no faults are present. - If any VFD segment should fail to light during the display segment test, the Compass/Mini-Trip Computer module is faulty and must be replaced. 4. If the first seven tests pass, the Compass/Mini-Trip Computer shall verify that all the required J1850 messages are present on the J1850 bus. If all required J1850 messages are present on the J1850 bus, or if the ignition switch is turned to the OFF position, the Compass/Mini-Trip Computer module will automatically return to normal operation. The required J1850 messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine OFF Duration message - Ambient Air Temperature message NOTE: The Fuel Used J1850 message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the Compass/Mini-Trip Computer to exit Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 6595 diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. Refer to Compass Variation Adjustment in the Service Procedures. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Refer to Compass Demagnetizing in the Service Procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 6596 Compass: Adjustments STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. Fig.1 Variance Settings To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number (Fig. 1). 2. Turn the ignition switch to the ON/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display 3. Press and hold the Reset push button down until "VAR" appears in the display. This takes about five seconds. 4. Momentarily depress and release the STEP push button to step through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the Reset push button to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Compass: Service and Repair Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement Compass/Mini-Trip Computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. See Compass Variation Adjustment in the Service Procedures. The compass module has 2 types of auto-calibration; Slow-Cal and Fast-Cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PCI bus data indicating that engine speed is greater than 0 rpm, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: 1. Drive the vehicle to an area away from any large metal objects or overhead power lines. 2. Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." See: Setting Magnetic Zone Variance 3. The ignition switch must be in the On position and the CMTC display must not be blank. 4. Press the C/T button to view the Compass/Temperature display. 5. Press and hold the RESET button until CAL is displayed, then release the button. 6. Drive slowly less than 5 mph (8 km/h) through one or two complete 360 degree circles. Each circle should not take less than 16 seconds to complete. 7. CAL will remain illuminated to alert the driver that the compass is in the calibration mode. 8. After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. See: Compass Demagnetizing Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 6599 Compass: Service and Repair Compass Demagnetizing STANDARD PROCEDURE - COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 mm (0.25 in.) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the OFF position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 cm (2 ft) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 cm (2 ft) from the screw head, disconnect the tool. Fig.2 Roof Demagnetizing Pattern 6. Place a piece of paper approximately 22 by 28 cm (8.5 by 11 in.), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header (Fig. 2). The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 cm (2 ft) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 mm (0.50 in.) between passes, move the tool at least 11 cm (4 in.) to each side of the roof center line, and 28 cm (11 in.) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 cm (2 ft) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures for the procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 6600 Compass: Service and Repair Compass/Mini-Trip Computer Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner (Refer to OVERHEAD CONSOLE - REMOVAL). 3. Remove the four screws that secure the compass mini-trip computer module to the overhead console housing. 4. Pull the compass mini-trip computer module away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the compass mini-trip computer module housing by pushing the connector firmly toward the left side of the overhead console housing. 6. Disconnect the overhead console wire harness connector from the compass mini-trip computer module connector receptacle. 7. Remove the compass mini-trip computer module from the overhead console housing. INSTALLATION 1. Position the compass mini-trip computer module onto the overhead console housing. 2. Reconnect the overhead console wire harness connector to the compass mini-trip computer module connector receptacle. 3. Engage the overhead console wire harness connector onto the mount on the compass mini-trip computer module housing by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 4. Install and tighten the four screws that secure the compass mini-trip computer module to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the overhead console onto the headliner. Refer to Overhead Console in the Removal and Installation for the procedures. 6. Reconnect the battery negative cable. NOTE: If a new compass mini-trip computer has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures for the procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 6601 Compass: Service and Repair Setting Magnetic Zone Variance SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Magnetic Zone Variance Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Locations Coolant Level Indicator Lamp: Locations The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Locations > Page 6605 Coolant Level Indicator Lamp: Description and Operation COOLANT LOW INDICATOR The coolant low indicator is located in the Information Center area of the instrument cluster, to the left of center. The coolant low indicator consists of a stenciled cutout of the words "LOW COOLANT" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "LOW COOLANT" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The coolant low indicator is serviced as a unit with the instrument cluster. The coolant low indicator gives an indication to the vehicle operator when the engine coolant level is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface PCI data bus. The coolant low indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the coolant low indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the coolant low indicator is illuminated for about two seconds as a bulb test. - Coolant Low Lamp-ON Message - Each time the cluster receives a message from the PCM indicating the engine coolant level is low, the coolant low indicator will be illuminated, and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine coolant level is not low, 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 coolant low indicator is cycled OFF and then ON again by the appropriate lamp-OFF and lamp-ON messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant level through the low coolant level switch, then sends the proper messages to the instrument cluster. For further diagnosis of the coolant low indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the low coolant level switch, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the coolant low indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Application and ID Cruise Control Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Cruise .................................................................................................................................................. ..................................................................... VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Application and ID > Page 6609 Cruise Control Indicator Lamp: Description and Operation A cruise indicator is standard equipment on all instrument clusters However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator consists of the word "CRUISE", which appears in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board, and is visible through a window with a smoked clear lens located in the lower left corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The word "CRUISE" appears in a blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The cruise indicator is serviced as a unit with the VFD in the instrument cluster. The cruise indicator gives an indication to the vehicle operator when the speed control system is turned ON, regardless of whether the speed control is engaged. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The cruise indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the cruise indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the cruise indicator is illuminated for about two seconds as a bulb test. - Cruise Lamp-ON Message - Each time the cluster receives a cruise lamp-ON message from the PCM indicating the speed control system has been turned ON, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a cruise lamp-OFF message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned on, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper cruise indicator lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the cruise indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the speed control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the cruise indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6614 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR A door ajar indicator is standard equipment on all instrument clusters However, on vehicles not equipped with this optional feature, this indicator is electronically disabled. The door ajar indicator is located in the Information Center area of the instrument cluster, to the left of center. The door ajar indicator consists of a s10cil-like cutout of the words "DOOR AJAR" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "DOOR AJAR" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the instrument cluster. The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Central Timer Module (CTM) over the Programmable Communications Interface (PCI) data bus. The door ajar indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever 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 door ajar indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the door ajar indicator is illuminated for about two seconds as a bulb test. - Door Ajar Lamp-ON Message - Each time the cluster receives a door ajar lamp-on message from the CTM indicating that a door is open or not completely latched, the door ajar indicator will be illuminated. The indicator remains illuminated until the cluster receives a door ajar lamp-OFF message from the CTM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the door ajar indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The CTM continually monitors the door ajar switches to determine the status of the doors. The CTM then sends the proper door ajar lamp-on and lamp-OFF messages to the instrument cluster. For further diagnosis of the door ajar indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the door ajar switches and circuits, (Refer to LAMPS/LIGHTING - INTERIOR/DOOR AJAR SWITCH - DIAGNOSIS AND TESTING). For proper diagnosis of the CTM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the door ajar indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6641 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6642 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6643 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation COMPASS / MINI-TRIP COMPUTER The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed time (ET) - shows the accumulated ignition-ON time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the HVAC control head. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If the RESET push button is depressed for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. Temperature The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the ON position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 6647 The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display mm and max temperatures of -40 °C (-40 °F) and 54 °C (130 °F). Fig. 10 Ambient Temperature Sensor AMBIENT TEMP SENSOR The ambient air temperature sensor is hardwired to the HVAC control and the HVAC control sends out a J1850 message to the overhead console. The ambient temperature sensor is a variable resistor (Fig. 5)mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the HVAC control head unit. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the HVAC control head unit. Based upon the resistance in the sensor, the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. UNIVERSAL TRANSMITTER On some models a Universal Transmitter transceiver is standard factory-installed equipment The universal transmitter transceiver is integral to the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons at the rear of the CMTC. The three universal transmitter push buttons can be easily identified by sight. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The universal transmitter operates on a non- switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the universal transmitter, see the owner's manual in the vehicle glove box. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 6651 Four Wheel Drive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Four Wheel Drive ................................................................................................................................. ............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations > Page 6652 Four Wheel Drive Indicator Lamp: Description and Operation SERVICE 4WD INDICATOR 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. The service 4WD indicator is located in the Information Center area of the instrument cluster, to the right of center. The service 4WD indicator consists of a stencil-like cutout of the words "SERVICE 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 "SERVICE 4WD" text 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. The service 4WD indicator gives an indication to the vehicle operator when the Transfer Case Control Module (TCCM) 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 TCCM over the Programmable Communications Interface (PCI) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster 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 Lamp-ON Message - Each time the cluster receives a lamp-on message from the TCCM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a service 4WD lamp-OFF message from the TCCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no messages from the TCCM for six seconds, the service 4WD indicator is illuminated by the instrument cluster to indicate a loss of TCCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TCCM. 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 TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system. The TCCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the TCCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the service 4WD indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Locations Fuel Gauge: Locations The fuel gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Locations > Page 6656 Fuel Gauge: Description and Operation A fuel gauge is standard equipment on all instrument clusters. The fuel gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The fuel gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from E (or Empty) to F (or Full). An International Control and Display Symbol icon for "Fuel" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the "Fuel" icon in the fuel gauge to provide the driver with a reminder as to the location of the fuel filler access. The fuel gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full, the cluster programming applies an algorithm to calculate the proper gauge needle position, then moves the gauge needle to the proper relative position on the gauge scale. The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the PCM. - Less Than 12.5 Percent Tank Full Message - Each time the cluster receives messages from the PCM indicating the percent tank full is about 12.5 (one-eighth) or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to the one-eighth graduation or below on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM indicating that the percent tank full is greater than about 12.5 (1/8) for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then ON again by the appropriate percent tank full messages from the PCM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is less than empty the gauge needle is moved to the far left (low) end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is a short circuit. - More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is more than full, the gauge needle is moved to the far left (low) end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is an open circuit. - Communication Error - If the cluster fails to receive a percent tank full message, it will hold the gauge needle at the last indication about 40 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 40 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the fuel tank sending unit, then sends the proper messages to the instrument cluster. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the fuel tank sending unit, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the fuel gauge, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6660 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 % of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 % of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6661 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges under Electrical for Fuel Gauge testing. To test the gauge sending unit only it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6662 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector (Fig. 3). b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6663 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch (Fig. 5). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab (Fig. 6) to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6664 module is located inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6669 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations Low Fuel Lamp/Indicator: Locations The low fuel indicator is located in the Information Center area of the instrument cluster overlay to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations > Page 6673 Low Fuel Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Fuel .............................................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations > Page 6674 Low Fuel Lamp/Indicator: Description and Operation A low fuel indicator is standard equipment on all instrument clusters. The low fuel indicator is located in the Information Center area of the instrument cluster overlay to the left of center. The low fuel indicator consists of a s10cil-like cutout of the International Control and Display Symbol icon for "Fuel" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The low fuel indicator Light Emitting Diode (LED) 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 low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. Less Than 12.5 Percent Tank Full Message - Each time the cluster receives messages from the PCM indicating the percent tank full is about 12.5 (one-eighth) or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to the one-eighth graduation or below on the gauge scale, the low fuel indicator is illuminated and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM indicating that the percent tank full is greater than about 12.5 (one-eighth) for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then ON again by the appropriate percent tank full messages from the PCM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is less than empty the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is a short circuit. More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is more than full, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The PCM continually monitors the fuel tank sending unit, then sends the proper messages to the instrument cluster. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the fuel tank sending unit, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the low fuel indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 6678 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ................................................................... LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 6679 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a 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 icon to appear in amber through the translucent outer layer of the overlay when the indicator 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. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) 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 seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-OFF message automatically Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters. - Communication Error - If the cluster receives no lamp-ON message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-on message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-OFF messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation An odometer and trip odometer are standard equipment in all instrument clusters. The odometer and trip odometer information are displayed in a common electronic, blue-green Vacuum-Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the left lower quadrant of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. However, the odometer and trip odometer information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch knob that extends through the lower edge of the cluster lens, just right of the odometer VFD. When the trip odometer information is displayed, the word "TRIP" is also illuminated in a blue-green color and at the same lighting level as the trip odometer information in the lower right corner of the VFD. The odometer and the trip odometer information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 999.9 kilometers (999.9 miles) before it rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. During daylight hours (exterior lamps OFF) the VFD is illuminated at full brightness for clear visibility At night (exterior lamps are ON) the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness while the exterior lamps are turned ON during daylight hours. The VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. This indicator is controlled by the instrument cluster electronic circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The odometer and trip odometer information is displayed by the instrument cluster Vacuum Fluorescent Display VFD). The VFD will not display odometer or trip odometer information after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer display Each time the VFD is illuminated with the ignition switch in the ON or Start positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). - Trip Odometer Reset - When the trip odometer reset switch is pressed and held for longer than about two seconds with the ignition switch in the ON or Start positions, the trip odometer will be reset to 0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - Communication Error - If the cluster fails to receive a distance message during normal operation, it will flash the odometer/trip odometer distance information on and off repeatedly until a distance message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. If the cluster does not receive a distance message within one second after the ignition switch is turned to the ON position, it will display the last distance message stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD display will be blank. - Actuator Test - Each time the cluster is put through the actuator test, the VFD will display all of its segments simultaneously, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry The PCM continually monitors the vehicle speed pulse information received from the vehicle speed sensor, then sends the proper distance messages to the instrument cluster. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the vehicle speed sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the odometer/trip odometer, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle did not have an Oil Change Reminder Light. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Application and ID > Page 6686 Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Application and ID > Page 6687 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations > Page 6691 Oil Pressure Gauge: Description and Operation OIL PRESSURE GAUGE An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication about forty seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine oil pressure .............................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 6698 Overdrive Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overdrive Off ....................................................................................................................................... .............................................................................. VF Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 6699 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is part of the cluster electronic circuit board and is visible through a window with a smoked clear lens located in the lower right corner of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when they are illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Locations Parking Brake Warning Lamp: Locations The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Locations > Page 6703 Parking Brake Warning Lamp: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster, to the right of center. The brake indicator consists of stencil-like cutouts of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) 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 brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-ON Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if a vehicle with an automatic transmission is not in Park or Neutral, or if the engine is running on vehicles with a manual transmission. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for three consecutive seconds, the brake indicator will be illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the CAB. Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper park brake status messages to the CAB. The CAB then sends the proper brake indicator lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). The park brake switch input to the CTM and the brake pressure switch input to the CAB may be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Central Timer Module ( CTM ) Low Option: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Central Timer Module ( CTM ) Low Option: Connector Views Central Timer Module C1 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Central Timer Module C2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 Central Timer Module C3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Central Timer Module ( CTM ) Low Option: Electrical Diagrams System Schematic Wiring Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 8w-45-2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 8w-45-3 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 8w-45-4 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 8w-45-5 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 8w-45-6 (Base/Premium) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 8w-45-7 (Midline/Highline) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 8w-45-8 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 8w-45-9 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 8w-45-10 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 8w-45-11 (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 8w-45-12 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 8w-45-13 (Premium 2 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 8w-45-14 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 8w-45-15 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 8w-45-16 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 8w-45-17 (Premium 4 Door) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 8w-45-18 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 8w-45-19 NOTE: To view sheets referred to in these diagrams, See Complete Body and Chassis Diagrams. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6748 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6749 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE The Dakota (AN) and (AN84) utilize a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. Fig.1 Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel (Fig. 1). The base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM are used on vehicles that are equipped with one or more of those options. The CTM utilizes circuitry, and information carried on the Programmable Communications Interface (PCI) data bus network, along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Base and Highline CTM supports or controls the following features: Automatic Door Lock - Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Low and High Beam Head Lamps - Optical Horn - Park Lamps - Speed Sensitive Intermittent Wiper Controls Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Horn Chirp - Optical Chirp - Panic Mode Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6750 - Power Door Locks - Programmable Features - Remote Keyless Entry - Remote Radio Switch Interface - Vehicle Theft Security System (VTSS) The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Programmable Communications Interface (PCI) data bus to control the volume, seek, and pre-set station advance functions of the optional radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. (Refer to BODY CONTROL/CENTRAL TIMER MODULE - DESCRIPTION) for more information on the high-line CTM. (Refer to REMOTE SWITCHES DESCRIPTION) for more information on this component. In addition, radio receivers connected to the PCI data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB III testing of the audio systems. Hard wired circuitry connects the CTM to the electrical system of the vehicle. Refer to the appropriate wiring information. All versions of the CTM for this model are serviced only as a complete unit. Many of the features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. If any of the CTM hardware components are damaged or faulty the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods. For diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. The Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The programming and all of the inputs allow the CTM to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM then performs those tasks and provides those features through both PCI data bus communication with other modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems. The CTM operates on battery voltage received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (RUN/START) circuit, and a fused ignition switch output (RUN/ACC) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position. The CTM is grounded to the chassis. Two of these ground circuits are on the left inner cowl panel near the CTM, while the third is near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store Diagnostic Trouble Codes (DTC) in memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Cargo lamp switch sense - Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch MUX - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (RUN/ACC) - Fused ignition switch output (RUN/START) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Low beam switch output - Park brake switch sense Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6751 - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch MUX - high line with power locks only - PCI bus circuit - Radio control MUX - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Cargo lamp driver - Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) - Ignition Staus - VTSS Status - Country Code Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6752 Central Timer Module ( CTM ) Low Option: Testing and Inspection The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the modules that provide inputs to, or receive outputs from, the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 6753 Central Timer Module ( CTM ) Low Option: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl inner panel. Fig.2 Central Timer Module 3. Disconnect the wiring harness connectors from the CTM. (Fig. 2). 4. Remove the screws that secure the CTM to the left cowl inner panel. 5. Remove the CTM from the left cowl inner panel. INSTALLATION NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl inner panel (Fig. 2). 2. Install and tighten the screws that secure the CTM to the left cowl inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wiring harness connectors to the CTM. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations Seat Belt Reminder Lamp: Locations The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 6757 Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Seat Belt .............................................................................................................................................. .................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 6758 Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator Light Emitting Diode (LED) 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 seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit, the indicator will be illuminated as a seatbelt reminder for about seven seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), then flash the seatbelt indicator ON and OFF. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch input to the instrument cluster circuitry can be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6783 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6784 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6785 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6789 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 % of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 % of its rated capacity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6790 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges under Electrical for Fuel Gauge testing. To test the gauge sending unit only it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6791 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 3 Fuel Gauge Sending Unit - 2 Door Models Fig. 4 Fuel Gauge Sending Unit Location - 4 Door Models The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. 2 Door Models: a. Unplug 4-way electrical connector (Fig. 3). b. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6792 Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2 Door Models c. The sending unit is retained to pump module with a small lock tab and notch (Fig. 5). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. 4. 4 Door Models: a.Remove electrical connector at sending unit terminals. Fig. 6 Fuel Gauge Sending Unit Release Tab - 4 Door Models b.Press on release tab (Fig. 6) to remove sending unit from pump module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 3) or (Fig. 4). The fuel pump Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6793 module is located inside of fuel tank. 1. 2 Door Models: a. Position sending unit into tracks. Note wire routing. b. Push unit on tracks until lock tab snaps into notch. c. Connect 2 sending unit wires into 4-way connector and install locking collar. d. Connect 4-way electrical connector to module. 2. 4 Door Models: a. Position sending unit to pump module and snap into place. b. Connect electrical connector to terminals. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations Speedometer Head: Locations The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations > Page 6797 Speedometer Head: Description and Operation SPEEDOMETER A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face that reads left-to-right either from 0 to 120 mph, or from 0 to 200 km/h, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just above the hub of the speedometer needle abbreviates the unit of measure for the primary scale (i.e.: MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics are white (primary scale) and blue (secondary scale) against a black field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the blue graphics appear blue. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. The speedometer gives an indication to the vehicle operator of the vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives a vehicle speed message from the PCM it will calculate the correct vehicle speed reading and position the gauge needle at that speed position on the gauge scale. The cluster will receive a new vehicle speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continue to be positioned at the actual vehicle speed position on the gauge scale until the ignition switch is turned to the OFF position. - Communication Error - If the cluster fails to receive a speedometer message, it will hold the gauge needle at the last indication for about four seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After four seconds, the gauge needle will return to the far left (low) end of the scale. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the vehicle speed sensor to determine the vehicle road speed, then sends the proper vehicle speed messages to the instrument cluster. For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the vehicle speed sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the speedometer, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations Tachometer: Locations The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 6801 Tachometer: Description and Operation A tachometer is standard equipment on all instrument clusters The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face that reads left-to-right from 0 to 7 for gasoline engines, or from 0 to 5 for diesel engines. The text "RPM X 1000" imprinted on the cluster overlay directly above the hub of the tachometer needle identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. The tachometer graphics are white against a black field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an engine speed message from the PCM it will calculate the correct engine speed reading and position the gauge needle at that speed position on the gauge scale. The cluster will receive a new engine speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continue to be positioned at the actual engine speed position on the gauge scale until the ignition switch is turned to the OFF position. - Communication Error - If the cluster fails to receive an engine speed message, it will hold the gauge needle at the last indication for about four seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After four seconds, the gauge needle will return to the far left (low) end of the scale. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the crankshaft position sensor to determine the engine speed, then sends the proper engine speed messages to the instrument cluster. For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the crankshaft position sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tachometer, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 6805 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to- right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 129 °C (264 °F)], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (252 °F), the gauge needle is moved into the red zone on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 122 °C (252 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate engine temperature messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about forty seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Locations > Page 6809 Temperature Warning Indicator - A/T: Description and Operation TRANS TEMP INDICATOR A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an automatic transmission, this indicator is electronically disabled. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencil-like cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by 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. 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 by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) 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 Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then ON again by the appropriate trans over-temp messages from the PCM. Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Upshift Indicator > Component Information > Locations Upshift Indicator: Locations The upshift indicator is located near the center of the tachometer gauge in the instrument cluster overlay, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Upshift Indicator > Component Information > Locations > Page 6813 Upshift Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Upshift ................................................................................................................................................. ......................................................... PLEDC74 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Upshift Indicator > Component Information > Locations > Page 6814 Upshift Indicator: Description and Operation An upshift indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with a manual transmission, this indicator is disabled. The upshift indicator is located near the center of the tachometer gauge in the instrument cluster overlay, to the left of center. The upshift indicator consists of an upward pointed arrow icon that is a stencil-like cutout 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 icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The upshift indicator is serviced as a unit with the instrument cluster. The upshift indicator gives an indication to the vehicle operator when the manual transmission should be shifted to the next highest gear in order to achieve the best fuel economy. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The upshift 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster transistor. On models not equipped with a manual transmission, a unique version of the instrument cluster is used that does not include the upshift indicator. The instrument cluster will turn ON the upshift indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the upshift indicator is illuminated for about two seconds as a bulb test. - Upshift Lamp-ON Message - Each time the cluster receives an upshift lamp-on message from the PCM indicating the engine speed and load conditions are right for a transmission upshift to occur, the upshift indicator is illuminated. The indicator remains illuminated until the cluster receives an upshift lamp-OFF message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. The PCM will normally send an upshift lamp-OFF message three to five seconds after a lamp-ON message, if an upshift is not performed. The indicator will then remain OFF until the vehicle stops accelerating and is brought back into the range of indicator operation, or until the transmission is shifted into another gear. - Actuator Test - Each time the cluster is put through the actuator test, the upshift indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine speed and load conditions to determine the proper fuel and ignition requirements. The PCM then sends the proper messages to the instrument cluster. For further diagnosis of the upshift indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the upshift indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation VOLTAGE GAUGE A voltage gauge is standard equipment on all instrument clusters The voltage gauge is located in the upper left quadrant of the instrument cluster, above the temperature gauge. The voltage gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to- right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Battery Charging Condition" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The voltage gauge graphics are white against a black field except for a single red graduation at each end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (RUN/START) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - System Voltage Message - Each time the cluster receives a system voltage message from the PCM indicating the system voltage is between about 11.5 volts and 16.0 volts, the gauge needle is moved to the relative position on the gauge scale. - System Voltage Low (Charge Fail) Message - Each time the cluster receives a message from the PCM indicating system voltage is less than about 11.5 volts (charge fail condition), the gauge needle is moved to the "L" graduation on the gauge scale and the check gauges indicator is illuminated. The gauge needle remains on the "L" graduation and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is greater than about 12.0 volts (but less than 16.0 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - System Voltage High Message - Each time the cluster receives a message from the PCM indicating the electrical system voltage is greater than about 16.0 volts, the gauge needle is moved to the "H" graduation on the gauge scale and the check gauges indicator is illuminated. The gauge needle remains on the "H" graduation and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than about 15.5 volts (but greater than 11.5 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication about forty seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After forty 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 gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the system voltage to control the generator output. The PCM then sends the proper system voltage messages to the instrument cluster. For further diagnosis of the voltage gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. For proper diagnosis of the charging system, the PCI data bus, or the electronic message inputs to the instrument cluster that control the voltage gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Application and ID Brake Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Tail/Brake/Turn Signal ......................................................................................................................... ................................................................. 3157 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6829 Brake Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6830 Brake Light Switch: Description and Operation The plunger type stop lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is used for the brake lamp, speed control and brake sensor circuits. The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits is closed until the plunger is depressed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6831 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6832 Brake Light Switch: Service and Repair REMOVAL Fig.2 Brake Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 ° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations Cargo Lamp: Locations The cargo lamp indicator is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 6836 Cargo Lamp: Diagrams C329 (Cargo Lamp Side) Cargo Lamp No.1 Cargo Lamp No.2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 6837 Cargo Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Cargo ................................................................................................................................................... .................................................................... 921 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 6838 Cargo Lamp: Description and Operation CARGO LAMP INDICATOR A cargo lamp indicator is standard equipment on all instrument clusters The cargo lamp indicator is located in the Information Center area of the instrument cluster overlay, to the left of center. The cargo lamp indicator consists of a stencil-like cutout of the words "CARGO LAMP" 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 "CARGO LAMP" text 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 cargo lamp indicator is serviced as a unit with the instrument cluster. The cargo lamp indicator gives an indication to the vehicle operator when the exterior cargo lamp is illuminated. This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon the cluster programming and electronic messages received by the cluster from the Central Timer Module (CTM) over the Programmable Communications Interface (PCI) data bus. The cargo lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever 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 cargo lamp indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the cargo lamp indicator is illuminated for about seven seconds as a bulb test. - Cargo Lamp-ON Message - Each time the cluster receives a lamp-on message from the CTM, the cargo lamp indicator will be illuminated. The indicator remains illuminated until the cluster receives a cargo lamp-OFF message from the CTM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cargo lamp indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The CTM continually monitors the cargo lamp switch circuitry of the headlamp switch through the cargo lamp switch sense circuit to determine the status of the cargo lamps. The CTM then sends the proper cargo lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the cargo lamp indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the CTM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the cargo lamp indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 6839 Cargo Lamp: Service and Repair REMOVAL The cargo lamp bulb is incorporated in the CHMSL assembly (Refer to LAMPS/ LIGHTING EXTERIOR/CENTER HIGH MOUNTED STOP LAMP - REMOVAL) for bulb replacement Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center Mounted Brake Lamp: Diagrams Center High Mounted Stop Lamp Left Tail/Stop/Turn Signal Lamp Right Tail/Stop/Turn Signal Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 6843 Center Mounted Brake Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Center High Mounted Stop lamp ......................................................................................................... .................................................................... 921 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 6844 Center Mounted Brake Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the CHMSL from the roof panel. 3. Rotate the sockets 1/4 turn clockwise and remove from lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Position socket in lamp and rotate socket 1/4 turn counterclockwise. 3. Install the CHMSL. 4. Connect battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Application and ID Console Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Overhead Console ............................................................................................................................... .................................................................... 192 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Glove Box Lamp And Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 6852 Glove Box Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 6853 Glove Box Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Glove Compartment ............................................................................................................................ .................................................................... 194 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 6854 Glove Box Lamp: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement to access and depress the retaining latches on the glove box lamp and switch housing. Fig.3 Glove Box Lamp And Switch 4. Push the glove box lamp and switch out through the mounting hole in the instrument panel and disconnect the wire harness connector. 5. Remove the glove box lamp and switch from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector. 2. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 3. Push the glove box lamp and switch into the mounting hole until the retaining latches are fully seated 4. Close the glove box 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams > Page 6858 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams > Page 6859 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement to access and depress the retaining latches on the glove box lamp and switch housing. Fig.3 Glove Box Lamp And Switch 4. Push the glove box lamp and switch out through the mounting hole in the instrument panel and disconnect the wire harness connector. 5. Remove the glove box lamp and switch from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector. 2. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 3. Push the glove box lamp and switch into the mounting hole until the retaining latches are fully seated 4. Close the glove box 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation Fog lamps Canada vehicles use daytime running lamps. Check wiring circuit from fog lamps DRL. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL Fig. 4 Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Fig.7 Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6890 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6891 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6892 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6897 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6898 Fog/Driving Lamp Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6899 Fog Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations The combination flasher is located under the instrument panel just outboard of the steering column opening. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6904 Combination Flasher Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6905 Hazard Warning Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6906 Hazard Warning Flasher: Description and Operation Fig.3 Combination Flasher COMBINATION FLASHER The combination flasher is located under the instrument panel just outboard of the steering column opening. The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The combination flasher controls the following inputs and outputs: fused B(+), fused ignition switch output, right turn signal sense, left turn signal sense, hazard flasher signal, brake lamp switch output, and two outputs each for the right and left turn signal circuits. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The Integrated Circuit (IC) within the combination flasher contains the logic that controls the flasher operation and the flash rate. The IC receives separate sense ground inputs from the multi-function switch for the hazard flasher, right turn signal, and left turn signal. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate. If the combination flasher is believed to be faulty test the turn signal and hazard warning system. Then replace the combination flasher with a known good unit to confirm system operation. (Refer to LAMPS/LIGHTING - EXTERIOR/ TURN SIGNAL & HAZARD WARNING SYSTEM - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6907 Hazard Warning Flasher: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig.4 Combination Flasher 2. Reach under the outboard side of the steering column opening and remove the combination flasher from the instrument panel wire harness connector.. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the combination flasher to the instrument panel wire harness connector. 2. Using hand pressure, push in firmly on the combination flasher until the terminals are fully seated in the instrument panel wire harness connector. 3. Align the slot in the combination flasher connector with the mounting tab on the instrument panel armature and install the flasher. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6911 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6912 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6913 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6918 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6919 Headlamp Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Headlamp Switch ................................................................................................................................. ................................................................... 158 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6920 Headlamp Switch: Description and Operation The headlamp switch controls the parking lamps, the headlamps, fog lamps,the interior lamps and the instrument cluster illumination. The headlamp switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are on and the driver door ajar switch is closed.The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. (Refer to HEADLAMP SWITCH - REMOVAL) for the service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6921 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Head Lamp Switch Continuity Table Fig.9 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6922 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations Hi-Beam Indicator Lamp: Locations The high beam indicator is located near the upper edge of the instrument cluster overlay, between the tachometer and the speedometer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 6926 Hi-Beam Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 6927 Hi-Beam Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application High Beam ........................................................................................................................................... .............................................................. PC194 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 6928 Hi-Beam Indicator Lamp: Description and Operation A high beam indicator is standard equipment on all instrument clusters. The high beam indicator is located near the upper edge of the instrument cluster overlay, between the tachometer and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "High Beam" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue lens behind the cutout in the opaque layer of the overlay causes the icon to appear in blue through the translucent outer layer of the overlay when it is illuminated from behind by a replaceable incandescent bulb and bulb holder unit located on the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. The high beam indicator gives an indication to the vehicle operator when the headlamp high beams are illuminated. This indicator is hard wired on the instrument cluster electronic circuit board, and is controlled by the Central Timer Module (CTM) through the high beam indicator driver circuit input to the cluster based upon a control signal to the CTM from the headlamp beam select switch. The headlamp beam select switch is integral to the multi-function switch on the left side of the steering column. The high beam indicator bulb receives battery current on the instrument cluster electronic circuit board through a fused B(+) circuit at all times; therefore, the indicator remains operational regardless of the ignition switch position. The indicator only illuminates when it is provided with a path to ground by the CTM. The high beam indicator can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the CTM and the inputs to the CTM that control the high beam indicator driver circuit, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 6929 Hi-Beam Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative headlamp high beam indicator condition. If the problem being diagnosed is related to inoperative headlamp high beams, be certain to repair the headlamp system before attempting to diagnose or repair the high beam indicator. If no headlamp system problems are found, the following procedure will help locate a short or open in the high beam indicator driver circuit. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Does Not Illuminate With High Beams Selected 1. Check the fused B(+) fuse (Fuse 1 - 15 ampere) in the Junction Block (JB). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse (Fuse 1 - 15 ampere) in the JB. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit between the JB and the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the instrument cluster from the instrument panel. Reconnect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the instrument panel wire harness connector (Connector C1) for the instrument cluster. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit between the instrument cluster and the JB as required. 4. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the high beam indicator driver circuit cavities of the instrument panel wire harness connector (Connector C1) for the CTM and the instrument panel wire harness connector (Connector C1) for the instrument cluster. There should be continuity. If OK, go to Step 5. If not OK, repair the open high beam indicator driver circuit between the instrument cluster and the CTM as required. 5. Reinstall the instrument cluster onto the instrument panel. Reconnect the battery negative cable. Install a jumper wire between the high beam indicator driver circuit cavity of the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. The indicator should illuminate. If OK, diagnose the CTM and its inputs using a DRB III scan tool. Refer to the appropriate diagnostic procedures. If not OK, replace the faulty high beam indicator bulb and bulb holder unit. Indicator Stays Illuminated With High Beams Not Selected 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the high beam indicator driver circuit cavity of the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. There should be no continuity If OK, diagnose the CTM and its inputs using a DRB III scan tool. Refer to the appropriate diagnostic procedures. If not OK, repair the shorted high beam indicator driver circuit between the CTM and the instrument cluster as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6934 Horn Relay: Diagrams Horn Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6935 Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6936 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6937 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6938 Horn Relay: Testing and Inspection Fig. 2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6939 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the Junction Block (JB). 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated. 5. Install the fuse access panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 6943 Horn Switch: Description and Operation Fig.3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane- type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly The horn switch is only serviced as a part of the driver side airbag trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag trim cover and horn switch must be replaced as a unit (Refer to /RESTRAINTS/DRIVER AIRBAG -REMOVAL) When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 6944 Horn Switch: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Application and ID Key Cylinder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Ignition Key .......................................................................................................................................... .................................................................... 53 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams License Plate Lamp: Diagrams C323 (License Lamp Side) Left License Lamp Right License Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 6951 License Plate Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application License Plate ....................................................................................................................................... .................................................................... 168 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement License Plate Lamp: Service and Repair License Plate Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable 2. From the underside of the bumper, grasp the bulb socket and rotate counter clockwise. 3. Pull bulb socket from lamp. 4. Grasp bulb and pull from socket. INSTALLATION 1. Position bulb in socket and press into place. 2. Position bulb socket in lamp and rotate clockwise to lock into place. 3. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement > Page 6954 License Plate Lamp: Service and Repair License Plate Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove license plate lamp bulb socket. 3. From the underside of the bumper and using a small flat blade, push in retaining tab to release the lamp from the bumper. 4. Separate lamp from bumper. INSTALLATION 1. Position lamp in bumper and press into place 2. Install license plate lamp bulb socket 3. Connect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb REMOVAL Fig. 4 Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Fig.7 Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams Marker Lamp: Diagrams Left Front Side Marker Lamp Front Front Side Marker Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 6962 Marker Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Front Side Marker ................................................................................................................................ ................................................................... 194 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 6967 Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 6968 Parking Lamp Relay: Diagrams Park Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6973 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6974 Fog/Driving Lamp Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6975 Fog Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6979 Horn Relay: Diagrams Horn Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6980 Junction Block (Front View) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6981 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6982 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6983 Horn Relay: Testing and Inspection Fig. 2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6984 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the Junction Block (JB). 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated. 5. Install the fuse access panel. 6. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 6988 Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 6989 Parking Lamp Relay: Diagrams Park Lamp Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6997 Brake Lamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6998 Brake Light Switch: Description and Operation The plunger type stop lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is used for the brake lamp, speed control and brake sensor circuits. The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits is closed until the plunger is depressed. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6999 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7000 Brake Light Switch: Service and Repair REMOVAL Fig.2 Brake Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 ° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the mounting housing on the steering column. (Refer to ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ MULTI-FUNCTION SWITCH - REMOVAL). Fig.15 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 7004 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER REMOVAL). 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure the upper shroud to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector. Fig.16 Multi-Function Switch 10. Remove the screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Remove the multi-function switch. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 N-m (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N-m (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper shroud and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N-m (20 in. lbs.). 9. Install tilt steering column knob. 10. Install the steering column opening cover onto the instrument panel. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 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 MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Fig. 12 Terminal Removal 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 (Fig. 12). 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. Diode Replacement REMOVAL Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. 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. 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. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Door Switch: Connector Views Driver Door Ajar Switch (Base) Driver Door Power Lock Motor/Ajar Switch (Except Base) Left Rear Door Ajar Switch (Base) Passenger Door Ajar Switch (Base) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Passenger Door Power Lock Motor/Ajar Switch (Except Base) Right Rear Door Ajar Switch (Base) Right Rear Door Power Lock Motor/Ajar Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Door Ajar Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7028 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7029 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state of the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Central Timer Module (CTM) when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7030 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground. 2. Check for continuity between the ground circuit and the driver or passenger door ajar switch sense circuit in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the appropriate body wire harness connector from the CTM. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM. 4. Check for continuity between the driver or passenger door ajar switch sense circuit of the body wire harness connector and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 7034 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 7035 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement to access and depress the retaining latches on the glove box lamp and switch housing. Fig.3 Glove Box Lamp And Switch 4. Push the glove box lamp and switch out through the mounting hole in the instrument panel and disconnect the wire harness connector. 5. Remove the glove box lamp and switch from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector. 2. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 3. Push the glove box lamp and switch into the mounting hole until the retaining latches are fully seated 4. Close the glove box 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7039 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7040 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7041 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7045 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7046 Headlamp Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Headlamp Switch ................................................................................................................................. ................................................................... 158 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7047 Headlamp Switch: Description and Operation The headlamp switch controls the parking lamps, the headlamps, fog lamps,the interior lamps and the instrument cluster illumination. The headlamp switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are on and the driver door ajar switch is closed.The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. (Refer to HEADLAMP SWITCH - REMOVAL) for the service procedures. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7048 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Head Lamp Switch Continuity Table Fig.9 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 7049 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7053 Horn Switch: Description and Operation Fig.3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane- type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly The horn switch is only serviced as a part of the driver side airbag trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag trim cover and horn switch must be replaced as a unit (Refer to /RESTRAINTS/DRIVER AIRBAG -REMOVAL) When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7054 Horn Switch: Testing and Inspection 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 AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7058 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7059 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7060 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams Tail Lamp: Diagrams C325 (Tail Lamp Side) C360 (Tail Lamp Side) Left Tail/Stop/Turn Signal Lamp Right Tail/Stop/Turn Signal Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 7064 Tail Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Tail/Brake/Turn Signal ......................................................................................................................... ................................................................. 3157 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement Tail Lamp: Service and Repair Tail Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove screws from tail lamp. 3. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. Fig.18 Tail, Brake, Turn Signal And 4. Remove sockets from tail lamp. 5. Pull bulb from socket. 6. Separate tail lamp from cargo box. INSTALLATION 1. Install bulb in socket. 2. Install socket in tail lamp. 3. Position tail lamp in cargo box, engage retaining studs and install screws. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 7067 Tail Lamp: Service and Repair Tail Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Release tailgate latch and open tailgate. Fig.19 Tail Lamp 3. Remove screw holding tail lamp to cargo box. 4. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. 5. Remove sockets from tail lamp. 6. Separate tail lamp from cargo box. INSTALLATION 1. Install sockets in tail lamp. Fig.20 Retaining Studs 2. Position tail lamp at cargo box, engage retaining studs and install screw. 3. Close tailgate. 4. Connect the negative battery cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the mounting housing on the steering column. (Refer to ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ MULTI-FUNCTION SWITCH - REMOVAL). Fig.15 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 7072 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER REMOVAL). 3. Remove the tilt steering column knob. 4. Remove the outboard screws that secure the upper shroud to the lower shroud. 5. Release the snap features that secure the upper shroud to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. Remove the center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector. Fig.16 Multi-Function Switch 10. Remove the screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Remove the multi-function switch. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 N-m (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector. 4. Position the lower shroud onto the steering column. 5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N-m (20 in. lbs.). 6. Position the upper shroud onto the steering column. 7. Align the snap features on the upper shroud and apply hand pressure to snap them together. 8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N-m (20 in. lbs.). 9. Install tilt steering column knob. 10. Install the steering column opening cover onto the instrument panel. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). 11. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations The combination flasher is located under the instrument panel just outboard of the steering column opening. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7076 Combination Flasher Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7077 Turn Signal Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7078 Turn Signal Flasher: Description and Operation Fig.3 Combination Flasher COMBINATION FLASHER The combination flasher is located under the instrument panel just outboard of the steering column opening. The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The combination flasher controls the following inputs and outputs: fused B(+), fused ignition switch output, right turn signal sense, left turn signal sense, hazard flasher signal, brake lamp switch output, and two outputs each for the right and left turn signal circuits. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The Integrated Circuit (IC) within the combination flasher contains the logic that controls the flasher operation and the flash rate. The IC receives separate sense ground inputs from the multi-function switch for the hazard flasher, right turn signal, and left turn signal. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate. If the combination flasher is believed to be faulty test the turn signal and hazard warning system. Then replace the combination flasher with a known good unit to confirm system operation. (Refer to LAMPS/LIGHTING - EXTERIOR/ TURN SIGNAL & HAZARD WARNING SYSTEM - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7079 Turn Signal Flasher: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig.4 Combination Flasher 2. Reach under the outboard side of the steering column opening and remove the combination flasher from the instrument panel wire harness connector.. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the combination flasher to the instrument panel wire harness connector. 2. Using hand pressure, push in firmly on the combination flasher until the terminals are fully seated in the instrument panel wire harness connector. 3. Align the slot in the combination flasher connector with the mounting tab on the instrument panel armature and install the flasher. 4. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations Turn Signal Indicator: Locations The turn signal indicators are located near the upper edge of the instrument cluster overlay, between the speedometer and the tachometer. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7083 Turn Signal Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7084 Turn Signal Indicator: Description and Operation Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster overlay, between the speedometer and the tachometer. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Turn Warning" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these icons from being clearly visible when their lamps are not illuminated. A green lens behind each cutout in the opaque layer of the causes the icon to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by a replaceable incandescent bulb and bulb holder unit located on the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by two individual hard wired inputs to the instrument cluster electronic circuit board. The turn signal indicator bulbs are grounded on the instrument cluster electronic circuit board at all times. The turn signal indicator bulbs only illuminate when they are provided with battery current by the turn signal and hazard warning circuitry of the combination flasher through separate left and right turn signal circuit inputs to the instrument cluster; therefore, these indicators can be illuminated, regardless of the ignition switch position. The turn signal indicators are connected in series between ground and the output of the combination flasher circuitry, but in parallel with the other turn signal circuits. This arrangement allows the turn signal indicators to remain functional regardless of the condition of the other circuits in the turn signal and hazard warning system. For more information on the turn signal and hazard warning system, (Refer to LAMPS/LIGHTING - EXTERIOR - OPERATION - TURN SIGNAL & HAZARD WARNING SYSTEM). The turn signal indicators can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7085 Turn Signal Indicator: Testing and Inspection The diagnosis found here addresses an inoperative turn signal indicator condition. If the problem being diagnosed is related to inoperative turn signals or hazard warning lamps, be certain to repair the turn signal and hazard warning system before attempting to diagnose or repair the turn signal indicators. If no turn signal or hazard warning system problems are found, the following procedure will help locate a short or open in the left or right turn signal indicator circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster from the instrument panel. 2. Reconnect the battery negative cable. Activate the hazard warning system by moving the hazard warning switch button on the multi-function switch to the ON position. Check for battery voltage at the inoperative (right or left) turn signal circuit cavity of the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be a switching (ON and OFF) battery voltage signal. If OK, replace the faulty turn signal indicator bulb. If not OK, repair the open (right or left) turn signal circuit between the instrument cluster and the combination flasher as required Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams Turn Signal Lamp: Diagrams Left Front Park/Turn Signal Lamp No.1 Left Front Park/Turn Signal Lamp No.2 Left Tail/Stop/Turn Signal Lamp Right Front Park/Turn Signal Lamp No.1 Right Front Park/Turn Signal Lamp No.2 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 7089 Right Tail/Stop/Turn Signal Lamp Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 7090 Turn Signal Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Turn Signal .......................................................................................................................................... ............................................................... PC194 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 7091 Turn Signal Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the park and turn signal lamp. Fig. 18 Park And Turn Signal Lamp Bulb 3. Rotate bulb socket 1/4 turn counterclockwise and remove the turn signal lamp socket from the back of the lamp. 4. Remove the park and turn signal lamp bulb from the socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7095 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7096 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTIFUNCTION SWITCH The multi-function switch is secured with screws to the multi-function switch mounting housing on the left side of the steering column..The switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. A single connector connects the switch to the vehicle electrical system. The multi-function switch supports the following functions and features: Continuous Wipe Modes - Hazard Warning Control - Headlamp Beam Selection - Headlamp Optical Horn - Intermittent Wipe Mode - Turn Signal Control - Washer Mode The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry The switch is grounded to the chassis near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery voltage is provided through a fused ignition switch output (RUN/ACC) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the switch provides a battery voltage output directly to the high or low speed brush of the wiper motor. When the control knob is in the Off position, the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to activate the hazard warning system, and pushed down again to turn the system off. The hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7097 - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides battery voltage through the washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Application and ID Underhood Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Underhood ........................................................................................................................................... .................................................................... 561 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Rear Window Defogger Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7106 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7107 Heated Glass Element Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7108 Rear Window Defogger Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly The rear window switch also contains the rear window defogger logic and timer circuitry, an LED defogger indicator lamp, the rear window defogger relay If faulty or damaged the entire controller assembly must be replaced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Rear Window Defogger Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7116 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7117 Heated Glass Element Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7118 Rear Window Defogger Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly The rear window switch also contains the rear window defogger logic and timer circuitry, an LED defogger indicator lamp, the rear window defogger relay If faulty or damaged the entire controller assembly must be replaced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Passenger Door Power Window Switch (Except Base) Right Rear Power Window Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7126 Power Window Switch: Description and Operation On conventional cab and club cab models, the power windows are controlled by two-way switches integral to the power window and lock switch bezel on the passenger side and the Driver Door Module on the driver side of the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger side window. On quad cab models, the power windows are controlled by four two-way switches and a power window lockout switch that are integral to the Driver Door Module on the driver side front door trim panel. Additionally each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. On all models, the power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. On quad cab models, when the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, on quad cab models the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7127 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED (s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors only). For diagnosis of the driver side power window switch (Refer to DOOR MODULE - DIAGNOSIS AND TESTING). Unplug the wire harness connector from the switch unit. Passenger Door Switch 4. Test the power window switch continuity See the Power Window Switch Continuity chart to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7128 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel. 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7133 Power Window Circuit Breaker: Testing and Inspection 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required If the circuit breaker checks OK, but no power windows operate refer to ALL WINDOWS INOPERATIVE Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams Power Window Motor: Diagrams Driver Door Power Window Motor (Except Base) Left Rear Power Window Motor Passenger Door Power Window Motor (Except Base) Right Rear Power Window Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7137 Power Window Motor: Description and Operation WINDOW MOTOR A permanent magnet reversible motor moves the window regulator through an integral gearbox mechanism. A positive and negative battery connection to the two motor terminals will cause the motor to rotate in one direction. Reversing the current through these same two connections will cause the motor to rotate in the opposite direction. In addition, each power window motor is equipped with an integral self-resetting circuit breaker to protect the motor from overloads. The power window motor and gearbox assembly cannot be repaired and, if faulty or damaged, the entire power window regulator assembly must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7138 Power Window Motor: Testing and Inspection 1. Disconnect and isolate the battery negative cable. Remove the trim panel from the door with the inoperative power window. 2. Unplug the power window motor wire harness connector. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the connections across the motor terminals to check the operation in the other direction. If the window is in the full up or full down position, the motor will not operate in that direction by design. If OK, repair the circuits from the power window motor to the power window switch as required. If not OK, replace the faulty motor. 3. If the motor operates in both directions, check the operation of the window glass and lift mechanism through its complete up and down travel. There should be no binding or sticking of the window glass or lift mechanism through the entire travel range. If not OK, refer to Body to check the window glass, tracks, and regulator for sticking, binding, or improper adjustment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7139 Power Window Motor: Service and Repair REMOVAL The power window motor and mechanism is integral to the power window regulator unit. If the power window motor or mechanism is faulty or damaged, the entire power window regulator unit must be replaced. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Passenger Door Power Window Switch (Except Base) Right Rear Power Window Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7143 Power Window Switch: Description and Operation On conventional cab and club cab models, the power windows are controlled by two-way switches integral to the power window and lock switch bezel on the passenger side and the Driver Door Module on the driver side of the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger side window. On quad cab models, the power windows are controlled by four two-way switches and a power window lockout switch that are integral to the Driver Door Module on the driver side front door trim panel. Additionally each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. On all models, the power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. On quad cab models, when the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, on quad cab models the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7144 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED (s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors only). For diagnosis of the driver side power window switch (Refer to DOOR MODULE - DIAGNOSIS AND TESTING). Unplug the wire harness connector from the switch unit. Passenger Door Switch 4. Test the power window switch continuity See the Power Window Switch Continuity chart to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7145 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel. 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Sliding Glass Back Window Glass: Service and Repair Backlite Sliding Glass REMOVAL Review Safety Precautions and Warnings paragraph at the front of this section before removing glass. 1. Remove B-pillar/quarter trim panels. 2. Remove cab back panel trim. 3. Bend backlite retaining tabs inward against glass. 4. Using a long knife from inside the vehicle cut urethane holding backlite frame to opening fence. 5. Separate glass from vehicle. INSTALLATION-SLIDING BACKLITE Review Safety Precautions and Warnings paragraph at the front of this section before removing glass. 1. Trim urethane adhesive from around rear glass opening fence leaving 1-2 mm of urethane on fence. 2. Apply RIM primer 25 mm (1 in.) wide to the mating surface of the backlite encapsulation. 3. Apply Gurit-Essex© Betawipe 4000 25 mm (1 in.) wide to the mating surface of the backlite encapsulation. 4. Apply blackout primer 25 mm (1 in.) wide to the mating surface of the backlite encapsulation. 5. Apply pinchweld primer 25 mm (1 in.) wide to the backlite opening fence. 6. Apply a 10 mm (0.4 in.) bead of urethane around perimeter of backlite along the inside of the encapsulation. 7. Position backlite into backlite opening using alignment pins in lower corners. 8. Firmly push glass against rear window glass opening fence. 9. Bend tabs around edges of backlite opening fence to retain glass. 10. Clean excess urethane from exterior with Mopar Super Clean or equivalent. 11. Install interior trim. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Sliding Glass > Page 7151 Back Window Glass: Service and Repair Backlite Vent Glass REMOVAL 1. Slide the upper run channel out of the window frame. 2. Slide the vent glass upward to remove from the lower window frame. 3. Lower the glass out of the upper window frame and remove. INSTALLATION 1. Slide the vent glass upper edge into window frame and insert the lower edge into the lower molding. 2. Position the upper run channel into the window frame and slide it into place. 3. Verify vent glass operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to glass regulator arm. 3. Remove inner door belt weatherstrip. 4. Remove outer door belt weatherstrip. 5. Lower glass to full down position and align glass regulator arm with access holes in inner door panel. 6. Remove front glass run channel. 7. Remove nuts attaching glass channel to regulator arm. 8. Separate glass from regulator arm. 9. Lift glass upward and out of opening at top of door. INSTALLATION 1. Slowly lower glass into door. 2. Position glass in regulator arm. 3. Install front glass run channel. 4. Install nuts attaching glass channel to regulator arm and tighten to 9 Nm (80 in. lbs.). 5. Ensure glass is aligned in run channels and tighten run channel bolts to 9 Nm (80 in. lbs.). 6. Install outer door belt weatherstrip. 7. Install inner door belt weatherstrip. 8. Reposition the water dam. 9. Install door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove inner beltline weatherstrip. 2. Remove outer beltline weatherstrip. 3. Remove the door waterdam. 4. Lower the window glass enough to access the regulator bolt. 5. Remove the window glass to regulator bolts. 6. Raise the window glass manually. 7. Remove the front lower glass run channel. 8. Lower the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 7158 9. Using a trim stick C-4755 or equivalent, pry up the inside edge of the quarter glass trim. 10. Partially remove front upper window weatherstrip. 11. Raise the glass and remove. INSTALLATION 1. Lower the glass into the door. 2. Install the front glass weatherstrip and the quarter glass trim. 3. Raise the glass manually and secure in the door frame. 4. Install the front lower glass channel. 5. Lower the glass, install the regulator bolts and tighten to 9 Nm (80 in. lbs.). 6. Cycle the glass to ensure proper operation. 7. Install the outer belt weatherstrip. 8. Install the inner belt weatherstrip. 9. Install the waterdam. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to access window regulator. 3. Remove glass from door. Fig.34 Power Regulator 4. Disengage power window motor wire connector from door harness, if equipped. Fig. 39 Power Regulator Bolts 5. Loosen bolts in slotted holes attaching regulator to door inner panel. 6. Remove bolts attaching window regulator to inner door panel. 7. Extract window regulator through access hole in inner door panel. 8. Separate window regulator from door panel. INSTALLATION 1. Position regulator in door and align bolts with slotted holes in door inner panel. 2. Install bolts attaching window regulator to inner door panel. 3. Engage power window motor wire connector to door harness, if equipped. 4. Install glass in door. 5. Install outer belt weatherstrip. 6. Install inner belt weatherstrip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 7163 7. Install water dam. 8. Install door trim panel. 9. Verify operation. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove the door inner trim panel. 2. Remove the door waterdam and speaker, if equipped. 3. Remove the inner and outer beltline weatherstrip. 4. Lower the door glass. 5. Remove the bolts attaching the regulator to the glass. 6. Raise the glass manually and secure in the door frame. 7. Loosen the regulator attachment nuts and remove the regulator attachment bolts. 8. Disengage regulator wire harness. Fig. 13 Rear Door Window Regulator 9. Remove the regulator. INSTALLATION 1. Position the window regulator in the door. 2. Install the fasteners attaching the regulator to the inner door panel. 3. Engage the regulator wire harness. 4. Lower the glass manually and install the bolts attaching the regulator to the glass. 5. Cycle the glass to ensure correct operation. 6. Install the inner and outer beltline weatherstrip. 7. Install the door waterdam and radio speaker, if equipped. 8. Install the door trim panel. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair Windshield: Service and Repair REMOVAL 1. Remove rear view mirror. 2. Remove the cowl grille. 3. With doors open, remove the weatherstrip from the side windshield moldings. 4. Remove the screws attaching the side windshield molding to the A-pillars. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 7170 5. Cut urethane bonding from around windshield using a suitable sharp cold knife. 6. Using a long knife, cut urethane bonding from inside the cab at the base of the windshield. INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 7171 The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 7172 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 7173 2. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart. 3. Clean inside of windshield with MOPAR Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lintfree cloth. 5. Apply the header molding to the windshield. 6. Apply pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 7174 7. Apply a 13mm (1/2 in.) high and 10mm (3/8 in.) wide bead of urethane around the perimeter of windshield. At the bottom, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the three sides where the molding is on the glass, follow the edge of molding. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator. 8. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. 9. Slowly lower windshield glass to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass onto fence along the A-Pillars. Push windshield inward to the fence at the bottom corners. 10. Clean excess urethane from exterior with MOPAR Super Clean or equivalent. 11. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 12. Install new screws attaching the side windshield moldings to the A-pillars. 13. Install the weatherstrip onto side windshield moldings. 14. Install cowl grille. 15. Install rear view mirror. 16. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair Check Valve: Service and Repair REMOVAL 1. Remove the wiper arms from the wiper pivots. (Refer to WIPER ARMS - REMOVAL). 2. Open the hood and pull the hood to plenum seal off of the forward flanges of the cowl grille cover and the plenum panel. 3. Remove the cowl plenum cover/grille panel from the top of the cowl plenum. 4. From the underside of the cowl plenum coven grille panel, disconnect the washer hoses from the three barbed nipples of the wye fitting/check valve unit. 5. Remove the wye fitting/check valve unit from the underside of the cowl plenum cover/grille panel. INSTALLATION 1. Position the wye fitting/check valve unit to the underside of the cowl plenum cover/grille panel. 2. From the underside of the cowl plenum cover/ grille panel, reconnect the three washer hoses to the barbed nipples of the wye fitting/check valve unit. 3. Reinstall the washer hoses for the washer nozzles into their locating clips on the underside of the cowl plenum cover/grille panel. 4. Reinstall the cowl plenum cover/grille panel onto the top of the cowl plenum panel. 5. Reinstall the wiper arms onto the wiper pivots. (Refer to WIPER ARMS INSTALLATION). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket- type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7183 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. (Refer to WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Remove/Install 4. Remove the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the wiper motor ground terminal. 8. Remove the wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the wiper arms onto the wiper pivots. (Refer to WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Front Wiper Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7187 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7188 Wiper Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7189 Front Wiper Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7190 Wiper Relay: Description and Operation The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. The wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the low speed brush of the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the wiper relay include: - The common feed terminal (30) is connected to the wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the wiper relay is de-energized, the common feed terminal is connected to the wiper park switch output through the CTM on the front wiper park switch sense circuit. The wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the wiper relay based upon its programming, inputs from the wiper and washer control circuitry of the multi-function switch, and inputs from the wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the ignition switch is in the On or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (RUN/ACC) current to the wiper motor low speed brush only when the wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the wiper motor low speed brush whenever the wiper relay control coil is de-energized and the Off position of the wiper control circuitry within the multi-function switch is selected. The wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7191 Wiper Relay: Testing and Inspection Fig.12 Wiper Relay The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. 1. Remove the wiper relay from the PDC. (Refer to WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (RUN/ACC) fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 87 of the wiper relay in the PDC whenever the ignition switch is in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (RUN/ACC) fuse in the JB through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 86 of the wiper relay in the PDC whenever the ignition switch is in the ON or ACCESSORY positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7192 Wiper Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.13 Power Distribution Centre - Typical 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for wiper relay identification and location. 4. Remove the wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper wiper relay location. 2. Position the wiper relay in the proper receptacle in the PDC. 3. Align the wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7197 Washer Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7198 Washer Fluid Level Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Washer Fluid ................................................................................................................................ ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7199 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7200 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig.2 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7201 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations Washer Fluid Level Indicator: Locations The washer fluid indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7205 Washer Fluid Level Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7206 Washer Fluid Level Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Washer Fluid ................................................................................................................................ ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7207 Washer Fluid Level Indicator: Description and Operation A washer fluid indicator is standard equipment on all instrument clusters. The washer fluid indicator is located in the Information Center area of the instrument cluster, to the right of center. The washer fluid indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Windshield Washer Fluid" in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the instrument cluster. The washer fluid indicator gives an indication to the vehicle operator when the fluid level in the washer fluid reservoir is low. This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming and a hard wired washer fluid level switch input to the cluster. The washer fluid indicator Light Emitting Diode (LED) 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 indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster transistor. The instrument cluster will turn on the washer fluid indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. - Washer Fluid Level Switch Input - Immediately after the bulb test, if the cluster senses ground on the washer fluid switch sense circuit for more than about thirty seconds, it turns ON the washer fluid indicator. Any time after the bulb test, the cluster must sense ground on the washer fluid switch sense circuit for more than about sixty seconds before it turns ON the indicator. Once illuminated, the indicator will remain illuminated until the ignition switch is cycled and the cluster senses an open circuit on the low washer fluid sense input. This strategy is intended to reduce the effect that fluid sloshing within the washer reservoir can have on reliable indicator operation. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The washer fluid level switch is connected in series between ground and the washer fluid switch sense input to the instrument cluster. For more information on the washer fluid level switch, (Refer to WIPERS/WASHERS/WASHER FLUID LEVEL SWITCH - OPERATION). For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). The washer fluid level switch input to the cluster can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7208 Washer Fluid Level Indicator: Testing and Inspection The diagnosis found here addresses an inoperative washer fluid indicator condition. If the problem being diagnosed is related to indicator accuracy, be certain to confirm that the problem is with the indicator or washer fluid level switch input and not with a damaged or empty washer fluid reservoir, or inoperative instrument cluster indicator control circuitry. Inspect the washer fluid reservoir for proper fluid level and signs of damage or distortion that could affect washer fluid level switch performance and perform the instrument cluster actuator test before you proceed with the following diagnosis. If no washer fluid reservoir or instrument cluster control circuitry problem is found, the following procedure will help to locate a short or open in the washer fluid switch sense circuit. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Does Not Illuminate With Washer Reservoir Empty 1. Disconnect and isolate the battery negative cable. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the washer fluid level switch connector receptacle. Check for continuity between the ground circuit cavity of the headlamp and dash wire harness connector for the washer fluid level switch and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G112) as required. 2. Remove the instrument cluster from the instrument panel. Check for continuity between the washer fluid switch sense circuit cavities of the headlamp and dash wire harness connector for the washer fluid level switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. If OK, replace the faulty washer fluid level switch. If not OK, repair the open washer fluid switch sense circuit between the washer fluid level switch and the instrument cluster as required. Indicator Stays Illuminated With Washer Reservoir Full 1. Disconnect and isolate the battery negative cable. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the washer fluid level switch connector receptacle. Check for continuity between the ground circuit terminal and the washer fluid switch sense terminal in the washer fluid level switch connector receptacle. There should be no continuity. If OK, go to Step 2. If not OK, replace the faulty washer fluid level switch. 2. Remove the instrument cluster from the instrument panel. Check for continuity between the washer fluid switch sense circuit cavity of the headlamp and dash wire harness connector for the washer fluid level switch and a good ground. There should be no continuity. If not OK, repair the shorted washer fluid switch sense circuit between the washer fluid level switch and the instrument cluster as required. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7212 Washer Fluid Level Switch Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7213 Washer Fluid Level Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Washer Fluid ................................................................................................................................ ................................................................. LED Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7214 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the washer pump/motor, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7215 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig.2 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7216 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation Windshield Washer Hose: Description and Operation WASHER HOSES/TUBES The washer plumbing consists of a small diameter rubber hose that is routed from the barbed outlet nipple of the washer pump/motor on the washer reservoir through the engine compartment along the headlamp and dash wire harness near the right inner fender shield to the dash panel. The washer hose passes from the engine compartment into the cowl plenum area through a dedicated hole with a rubber grommet near the right end of the cowl plenum panel. Beneath the cowl plenum cover/grille panel, a molded plastic in-line fitting with barbed nipples joins the engine compartment hose to a cowl plenum cover/grille panel hose. The cowl plenum cover/grille panel hose is routed through locating clips molded to the underside of the cowl plenum cover/ grille panel to a molded plastic wye fitting with barbed nipples and an integral check valve near the passenger side washer nozzle. Two hoses are then routed from the wye fitting through additional locating clips on the underside of the cowl plenum cover/ grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations The washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7223 Front Washer Pump/Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7224 Windshield Washer Motor: Description and Operation WASHER PUMP/MOTOR The washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in the dedicated mounting hole near the bottom of the washer reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the washer hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer pump/motor receives battery current on a front washer pump/motor control circuit through an output of the Central Timer Module (CTM) whenever the CTM receives an input through the closed contacts of the momentary washer switch within the multi-function switch. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7225 Windshield Washer Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.3 Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the washer hose to the barbed outlet nipple of the washer pump. 5. Reconnect the headlamp and dash wire harness connector for the washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure 7. Reconnect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations The washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7229 Front Washer Pump/Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7230 Windshield Washer Pump: Description and Operation WASHER PUMP/MOTOR The washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in the dedicated mounting hole near the bottom of the washer reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the washer hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer pump/motor receives battery current on a front washer pump/motor control circuit through an output of the Central Timer Module (CTM) whenever the CTM receives an input through the closed contacts of the momentary washer switch within the multi-function switch. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7231 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.3 Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the washer hose to the barbed outlet nipple of the washer pump. 5. Reconnect the headlamp and dash wire harness connector for the washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure 7. Reconnect the battery negative cable Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations Windshield Washer Reservoir: Locations The molded plastic washer fluid reservoir is integral to, and located on the right end of the upper radiator shroud in the right front corner of the engine compartment. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7235 Windshield Washer Reservoir: Description and Operation Fig.4 Washer Reservoir The molded plastic washer fluid reservoir is integral to, and located on the right end of the upper radiator shroud in the right front corner of the engine compartment. A bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon for "Windshield Washer" and the text "Washer Fluid Only" molded into it snaps over the open end of the filler neck. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just inboard of the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. There are separate, dedicated holes on the outboard side of the reservoir provided for the mounting of the washer/ pump motor unit and the washer fluid level switch. The washer reservoir is serviced only as a unit with the upper radiator shroud. The washer reservoir cannot be repaired and, if faulty or damaged, the upper fan shroud unit must be replaced. The grommet seals for the washer pump/motor unit and the washer fluid level switch, and the filler cap are each available for service replacement. The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, before the washer system will no longer operate. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7236 Windshield Washer Reservoir: Service and Repair REMOVAL Fig.5 Upper Fan Shroud Remove/Install NOTE: The washer reservoir is integral to the right end of the upper radiator shroud, and the engine coolant reserve/overflow tank is integral to the left end of the upper radiator shroud. 1. Disconnect and isolate the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7237 Fig.6 Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. 3. Disconnect the headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle. 4. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 5. Disconnect the engine coolant reserve/overflow hose from the nipple of the radiator filler spout in the upper radiator hose. 6. Remove the six screws that secure the upper radiator shroud to the radiator. 7. Disengage the locator dowels on the bottom of the upper radiator shroud from the locator holes in the upper flanges of the lower shroud. 8. Remove the upper radiator shroud from the radiator. INSTALLATION NOTE: The washer reservoir is integral to the right end of the upper radiator shroud, and the engine coolant reserve/overflow tank is integral to the left end of the upper radiator shroud. 1. Position the upper radiator shroud onto the radiator. 2. Engage the locator dowels on the bottom of the upper radiator shroud into the locator holes in the upper flanges of the lower shroud. 3. Install and tighten the six screws that secure the upper radiator shroud to the radiator. Tighten the screws to 6 Nm (50 in. lbs.). 4. Reconnect the engine coolant reserve/overflow hose to the nipple of the radiator filler spout in the upper radiator hose. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor. 6. Reconnect the headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle. 7. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 8. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation The two washer nozzles have integral snap features that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield. The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice is oriented towards the windshield glass. The washer plumbing fittings for the washer nozzles are concealed beneath the cowl plenum cover/grille panel. These fluidic washer nozzles are constructed of molded plastic. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. The washer nozzles incorporate a fluidic design, which causes the nozzle to emit the pressurized washer fluid as an oscillating stream to more effectively cover a larger area of the glass area to be cleaned. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7241 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Remove the wiper arms from the wiper pivots. (Refer to WIPER ARMS - REMOVAL). 2. Remove the cowl plenum cover/grille panel from the top of the cowl plenum. 3. From the underside of the cowl plenum cover/ grille panel, disconnect the washer hose from the nozzle fitting. 4. From the underside of the cowl plenum cover/ grille panel, compress the snap features of the washer nozzle and push the nozzle out through the top of the panel. INSTALLATION 1. Align the washer nozzle with the opening on the top of cowl plenum cover/grille panel. 2. Using hand pressure, push the washer nozzle into the opening from the top of the cowl plenum cover/grille panel until the snap features of the nozzle are fully engaged. 3. From the underside of the cowl plenum cover/ grille panel, reconnect the washer hose to the nozzle fitting. 4. Reinstall the cowl plenum cover/grille panel onto the top of the cowl plenum. 5. Reinstall the wiper arms onto the wiper pivots. (Refer to WIPER ARMS - INSTALLATION) Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations Wiper Arm: Locations The wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations > Page 7245 Wiper Arm: Description and Operation The wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arm has a die cast metal pivot end with a large mounting hole with internal serrations at one end. A molded black plastic cap fits over the wiper arm retaining nut to conceal the nut and this mounting hole following wiper arm installation. The wide end of a tapered, stamped steel channel hinges on and is secured with a hinge pin to the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap, with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook. Concealed within the stamped steel channel, one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The mounting hole formation with internal serrations in the wiper arm pivot end interlocks with the serrations on the outer circumference of the wiper pivot driver, allowing positive engagement and finite adjustment of this connection. The mounting nut locks the wiper arm to the threaded stud on the wiper pivot. The spring- loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations > Page 7246 Wiper Arm: Service and Repair REMOVAL 1. Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot connection. 2. Open the hood of the vehicle. Fig.7 Wiper Arm Remove/Install 3. Carefully pry the plastic nut cap off of the pivot end of the wiper arm. 4. Remove the nut that secures the wiper arm to the wiper pivot shaft. Wiper Arm Puller 5. Use a suitable battery terminal puller to disengage the wiper arm from the wiper pivot shaft splines. 6. Remove the wiper arm pivot end from the wiper pivot. INSTALLATION NOTE: Be certain that the wiper motor is in the park position before attempting to install the wiper arms. Turn the ignition switch to the ON position and move the multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations > Page 7247 Wiper Arm Installation 1. The wiper arms must be indexed to the wiper pivots with the wiper motor in the park position to be properly installed. Position the wiper arm pivot ends onto the wiper pivots so that the lower edge of the blade is aligned with the wiper alignment lines concealed in the upper margin of the lower windshield blackout area ± 15 mm (± 0.59 in.). 2. Once the wiper blade is aligned, lift the wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot hole on the end of the wiper arm down over the wiper pivot shaft. 3. Install and tighten the nut that secures the wiper arm to the wiper pivot shaft. Tighten the nut to 23.7 Nm (210 in. lbs.). 4. Wet the windshield glass, then operate the wipers. Turn the wiper switch to the OFF position, then check for the correct wiper arm position and readjust as required 5. Reinstall the plastic nut cap onto the wiper arm pivot nut Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7261 Wiper Blade: Description and Operation Each wiper blade is secured by an integral latching pivot block to the hook formation on the tip of the wiper arms, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. The driver side and passenger side wiper blades are not interchangeable. The superstructure of the driver side blade features an additional bridge, which provides an additional set of claws to retain the wiper squeegees. Their are eight sets of claws on the driver side, and six sets of claws used on the passenger side. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. All Dakota truck models have two 50 centimeter (19.69 inch) wiper blades with non-replaceable rubber elements (squeegees). These wiper blades also include an anti-lift feature. The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The wiper blade is moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7262 Wiper Blade: Service and Repair REMOVAL NOTE: The driver side and passenger side wiper blades are not interchangeable. The driver side wiper blade has an extra bridge and eight pairs of claws securing the wiper element. The passenger side wiper blade has six pairs of claws securing the wiper element. The notched retainer end of both wiper elements should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Turn the wiper control knob on the end of the multi-function switch control stalk to the ON position. Cycle the wiper blades to a convenient working location on the windshield by turning the ignition switch to the ON and OFF positions. 2. Lift the wiper arm to raise the wiper blade and element off of the glass. Wiper Blade Remove/Install - Typical 3. To remove the wiper blade from the wiper arm, push the pivot block latch release tab under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook. 4. Extract the hook formation on the tip of the wiper arm from the opening in the wiper blade superstructure ahead of the wiper blade pivot block/latch unit. CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. 5. Gently lower the wiper arm tip onto the glass. INSTALLATION NOTE: The driver side and passenger side wiper blades are not interchangeable. The driver side wiper blade has an extra bridge and eight pairs of claws securing the wiper element. The passenger side wiper blade has six pairs of claws securing the wiper element. The notched retainer end of both wiper elements should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm off of the windshield glass. 2. Position the wiper blade near the hook formation on the tip of the arm with the notched retainer for the wiper element oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure ahead of the wiper blade pivot block/ latch unit far enough to engage the pivot block with the hook. 4. Slide the wiper blade pivot block/latch up into the hook formation on the tip of the wiper arm until the latch release tab snaps into its locked position. 5. Gently lower the wiper blade onto the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket- type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7266 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. (Refer to WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Remove/Install 4. Remove the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the wiper motor ground terminal. 8. Remove the wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the wiper arms onto the wiper pivots. (Refer to WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect Technical Service Bulletin # D22 Date: 040701 Recall - Windshield Wiper Motor Defect July 2004 Dealer Service Instructions for: Safety Recall D22 - Windshield Wiper Motor 2002-2004 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from April 24, 2002 through September 15, 2003 (MDH 0424XX through 0915XX). 2002-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built after April 24, 2002 (MDH 0424XX). IMPORTANT: Vehicles that have already had the proper wiper module installed, according to warranty records, have been excluded from this recall. In addition, 2000 through early-2002 model year vehicles (built through April 23, 2002 (MDH 0423XX)) that have had a suspect replacement wiper module installed, according to warranty records, have been added to this recall. Dealers are also requested to review their records and contact owners who have purchased a wiper module or who have had a wiper module installed outside of the warranty provisions (P/N 55154863AF or 55154863AG). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Water may enter into the windshield wiper motor on about 310,000 of the above vehicles and cause the windshield wiper system to become inoperative. This can impair the driver's vision and cause a crash without warning. Repair The windshield wiper module must be replaced on all involved vehicles. Parts Information Each dealer to whom vehicles in the recall were invoiced will receive enough windshield wiper modules to service about 5% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7275 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule an appointment for this service with their dealer. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Remove the wiper arm plastic nut caps and then remove the left and right wiper arms. 3. Remove the cowl weatherstrip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7276 4. Remove the six (6) cowl grille plastic nuts and two (2) cowl grille push pins (Figure 1). 5. Disconnect the windshield washer hose and vacuum reservoir hose from the cowl grille. 6. Remove the cowl grille and set it aside (Figure 1). 7. Remove the four (4) wiper module screws (Figure 2). 8. Disconnect the wiper motor electrical connector (Figure 2). 9. Remove the wiper module and discard it. 10. Install the new wiper module into the vehicle. 11. Connect the wiper motor electrical connector (Figure 2). 12. Install the wiper module screws (Figure 2). Tighten the screws to 72 in-lbs (8 N.m). 13. Install the cowl grille (Figure 1). 14. Connect the windshield washer hose and vacuum reservoir hose to the cowl grille. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7277 15. Secure the cowl grille with the six (6) plastic nuts and two (2) push pins (Figure 1). 16. Install the cowl weatherstrip. 17. Install the wiper arms. Tighten the wiper arm nuts to 18 ft-lbs (24 N.m) and then install the plastic nut caps. NOTE: Ensure that the wiper arms are installed on the proper side of the vehicle. The arms are marked DS (driver side) and PS (passenger side) on the back of the arm. Be sure to align the wiper arms with the marks on the windshield. 18. Close the hood. 19. Activate the windshield washer system to ensure it functions properly. Cycle the wipers through all speeds, check the wipe pattern and adjust the wiper position(s) if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7278 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > NHTSA04V216000 > May > 04 > Recall 04V216000: Wiper Module Replacement Wiper Motor: Recalls Recall 04V216000: Wiper Module Replacement DEFECT: On certain pickup trucks and sport utility vehicles, the front windshield wiper module motor may be susceptible to water intrusion that could cause internal corrosion and result in partial or complete loss of front windshield wiping capability. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will replace the front windshield wiper module. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect Technical Service Bulletin # D22 Date: 040701 Recall - Windshield Wiper Motor Defect July 2004 Dealer Service Instructions for: Safety Recall D22 - Windshield Wiper Motor 2002-2004 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from April 24, 2002 through September 15, 2003 (MDH 0424XX through 0915XX). 2002-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built after April 24, 2002 (MDH 0424XX). IMPORTANT: Vehicles that have already had the proper wiper module installed, according to warranty records, have been excluded from this recall. In addition, 2000 through early-2002 model year vehicles (built through April 23, 2002 (MDH 0423XX)) that have had a suspect replacement wiper module installed, according to warranty records, have been added to this recall. Dealers are also requested to review their records and contact owners who have purchased a wiper module or who have had a wiper module installed outside of the warranty provisions (P/N 55154863AF or 55154863AG). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Water may enter into the windshield wiper motor on about 310,000 of the above vehicles and cause the windshield wiper system to become inoperative. This can impair the driver's vision and cause a crash without warning. Repair The windshield wiper module must be replaced on all involved vehicles. Parts Information Each dealer to whom vehicles in the recall were invoiced will receive enough windshield wiper modules to service about 5% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7288 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. 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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. 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. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule an appointment for this service with their dealer. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Remove the wiper arm plastic nut caps and then remove the left and right wiper arms. 3. Remove the cowl weatherstrip. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7289 4. Remove the six (6) cowl grille plastic nuts and two (2) cowl grille push pins (Figure 1). 5. Disconnect the windshield washer hose and vacuum reservoir hose from the cowl grille. 6. Remove the cowl grille and set it aside (Figure 1). 7. Remove the four (4) wiper module screws (Figure 2). 8. Disconnect the wiper motor electrical connector (Figure 2). 9. Remove the wiper module and discard it. 10. Install the new wiper module into the vehicle. 11. Connect the wiper motor electrical connector (Figure 2). 12. Install the wiper module screws (Figure 2). Tighten the screws to 72 in-lbs (8 N.m). 13. Install the cowl grille (Figure 1). 14. Connect the windshield washer hose and vacuum reservoir hose to the cowl grille. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7290 15. Secure the cowl grille with the six (6) plastic nuts and two (2) push pins (Figure 1). 16. Install the cowl weatherstrip. 17. Install the wiper arms. Tighten the wiper arm nuts to 18 ft-lbs (24 N.m) and then install the plastic nut caps. NOTE: Ensure that the wiper arms are installed on the proper side of the vehicle. The arms are marked DS (driver side) and PS (passenger side) on the back of the arm. Be sure to align the wiper arms with the marks on the windshield. 18. Close the hood. 19. Activate the windshield washer system to ensure it functions properly. Cycle the wipers through all speeds, check the wipe pattern and adjust the wiper position(s) if necessary. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > D22 > Jul > 04 > Recall - Windshield Wiper Motor Defect > Page 7291 Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > NHTSA04V216000 > May > 04 > Recall 04V216000: Wiper Module Replacement Wiper Motor: All Technical Service Bulletins Recall 04V216000: Wiper Module Replacement DEFECT: On certain pickup trucks and sport utility vehicles, the front windshield wiper module motor may be susceptible to water intrusion that could cause internal corrosion and result in partial or complete loss of front windshield wiping capability. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will replace the front windshield wiper module. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact DaimlerChrysler at 1-800-853-1403. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 7296 Front Wiper Motor Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Front Wiper Relay is located in the Power Distribution Center (PDC). Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7300 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7301 Wiper Relay: Diagrams Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7302 Front Wiper Relay Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7303 Wiper Relay: Description and Operation The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. The wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the low speed brush of the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the wiper relay include: - The common feed terminal (30) is connected to the wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the wiper relay is de-energized, the common feed terminal is connected to the wiper park switch output through the CTM on the front wiper park switch sense circuit. The wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the wiper relay based upon its programming, inputs from the wiper and washer control circuitry of the multi-function switch, and inputs from the wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the ignition switch is in the On or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit whenever the wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (RUN/ACC) current to the wiper motor low speed brush only when the wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the wiper motor low speed brush whenever the wiper relay control coil is de-energized and the Off position of the wiper control circuitry within the multi-function switch is selected. The wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Dakota Quad Cab 4wd Workshop Manual (V8-4.7L VIN N (2002)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7304 Wiper Relay: Testing and Inspection Fig.12 Wiper Relay The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and location. 1. Remove the wiper relay from the PDC. (Refer to WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (RUN/ACC) fuse in the Junction Block (JB) through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 87 of the wiper relay in the PDC whenever the ignition switch is in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (RUN/ACC) fuse in the JB through a fused ignition switch output (RUN/ACC) circuit. There should be battery voltage at the receptacle for terminal 86 of the wiper relay in the PDC whenever the ignition switch is in the ON or ACCESSORY positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (RUN/ACC) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required.